Sealant compositions and sealed electrical connectors

ABSTRACT

Disclosed are sealant compositions having excellent slump and spew resistance, even at relatively high operating temperatures for electrical connectors. The sealants, which are flowable at such elevated temperatures, comprise two essential components: elastomeric thermoplastic polymer, preferably an organic polymer composite comprising diblock and triblock copolymers, and extender for the polymer. The extender may comprise a primary and a secondary extender, such as polybutene oil and mineral oil, respectively.

This application is a continuation-in-part of copending U.S. applicationSer. No. 07/749,373, filed Aug. 23, 1991.

FIELD OF THE INVENTION

The present invention relates to novel polymer-containing compositions,electrical connectors which include said compositions as functionalcomponents, and methods of making such compositions. More particularly,this invention relates to compositions useful to seal and repairelectrical connectors.

BACKGROUND OF THE INVENTION

Quality and durability are important factors in the design of systemsfor providing electrical connections, especially such systems utilizedin the telecommunications and automotive industries. One criterionaffecting the quality of such connections is the extent of effectiveelectrical insulation surrounding the connection. Another importantcriterion is the maintenance of the connection in a moisture freeenvironment. The invasion of water at the connection site is detrimentalin several respects. For example, the "noise," "static" and "cross-talk"which frequently plague telecommunication systems are sometimes causedby signal leakage due to moisture at the connection site. The intrusionof water also has the obvious disadvantage of fostering corrosion andthus negatively impacting on the durability of the connection.

It is also desirable that electrical connections possess the ability toremain in a moisture free, non-corrosive environment when subjected toexternally applied shock, vibration and temperature stresses.

While noise resistance, durability and moisture resistance in the faceof environmental variations and other stresses is desirable in nearlyall electrical connecting devices, there are also many commercial andmilitary applications which require that electrical connections berepaired and/or modified in the field, It is highly desirable that suchrepair and/or modification be accomplished in the shortest period oftime, in an economically efficient fashion and with a minimum ofinconvenience to the field craftsperson or technician. In fact, suchcharacteristics are also highly desirable from the standpoint of theinitial manufacture of the electrical connecting device.

Nevertheless, many prior art devices and the sealant compositions usedtherein possess the disadvantage of being time consuming andinconvenient to manufacture and repair. For example, U.S. Pat. No.3,897,129--Ferrar is directed to an apparatus for protecting electricalcontacts by covering the contacts with a grease filled container. Whenrepair or replacement of the connection requires reentry to the sealedcontact, the container is removed from the contact. Disadvantageously,however, grease remains coated on the contact. This grease must beremoved before the repair and/or modification can be effected, anundesirably messy and time-consuming task. Furthermore, the containermust be refilled with grease prior to completion of the repair work.

It is also known to encapsulate electrical contacts within a containerby means of a two-part liquid composition. When mixed together, the twocomponents react slowly to produce a hard, relatively inflexiblematerial. Before the ingredients set, the mixture is poured into thecontainer where it cures in situ to form a hard, rigid plastic. U.S.Pat. Nos. 4,375,521--Arnold and 4,102,716--Graves disclose such devices.The procedure required by these devices, however, involves the obviouslyundesirable requirement that the composition be prepared under theconditions existing at the field location, thereby delaying andaffecting the quality of the repair and/or modification. Moreover, thephysical characteristics of the cured material are such that access tothe actual contact is inhibited. Additionally, the chemical curingreaction is controlled by the ambient temperature, proceeding slowly orincompletely at low temperature and being inconveniently rapid at hightemperatures.

Applicants have noted a failure of the prior art to provide devices andcompositions which overcome the disadvantages described above whilemaintaining the stringent requirements of noise, moisture andtemperature cycling resistance and environmental benignity andstability. Applicants have discovered novel polymer containingcompositions which satisfy the long-demanded need for materialspossessing this set of desirable characteristics.

Certain organic polymers are known to exhibit unique combinations ofproperties. Among these are block copolymers composed of polymer chainscomprised of at least two different types of polymeric units, in whichsequences (blocks) of one type of polymeric unit alternate withsequences of another type. If combined with the proper polymericarchitecture, the resulting polymeric materials exhibit propertiesdistinct and superior to those of each individual repeating component.For example, it is known that certain performance profiles such as heatresistance, thermoplasticity and elastomeric properties which are notattainable singly or in combination with homopolymers or even withrandom copolymers are attainable with such block copolymers orcombinations thereof.

U.S. Pat. No. 3,265,765--Holden et al describes thermoplastic elastomerscomprising block copolymers of the A-B-A configuration. Each A block isa glassy or resinous non-elastomeric thermoplastic polymer sequence andeach B block is an elastomeric polymer block of a conjugated dienehaving a glass transition temperature considerably below the glasstransition temperature of block A.

U.S. Pat. No. 4,942,270 to Gamarra is said to be directed to providingheat resistant gels without the necessity of using electron beamradiation. The compositions of Gamarra arepoly(styrene-ethylene-butylene-styrene) triblock copolymer-oilcompositions. The compositions contain about 2 to about 30 parts byweight of a triblock copolymer and about 70 to about 98 parts by weightof a plasticizer. Polybutene oil and paraffinic/naphthenic oils ormixtures of these oils are disclosed as examples of plasticizer.

Preparation of the Gamarra compositions requires high temperature meltblending or high shear blending at lower temperatures. The need for hightemperature/high shear blending of the Gamarra compositions is anobvious disadvantage in the preparation of these compounds. Anothersignificant disadvantage of the Gamarra compositions is that suchcompositions are described as being nonmeltable. That is, thesecompositions will degrade, decompose or break down in some manner beforethey reach a temperature at which the composition will melt and becomepourable. This is a disadvantage in the manufacture of sealed electricalconnectors because of limited process flexibility. Furthermore, therepair or replacement of sealed electrical connectors containing suchcompositions would also be hampered by such characteristics.

Shell Chemical Company Technical Bulletin SC:759-85 provides technicalinformation on KRATON G 1701, a diblock copolymer. This bulletinindicates that KRATON G 1701 is compatible with KRATON G 1652, atriblock copolymer, and that blends of the two polymers can be fomulatedto provide sealants with lower cohesive strength than KRATON G 1652alone. The use of such materials in electrical connectors is notsuggested nor is the means to provide permanently non-volatileformulations suggested.

The use of KRATON G Rubbers in clear sealants is presented in a July1987 Shell Chemical Company Technical Bulletin entitled "KRATON GRubbers in Clear Sealants." This report indicates that diblockcopolymers such as KRATON G 1701x provide a means to tailor the adhesionand cohesive strength of a sealant composition. The diblock copolymerKRATON G 1701x is also said to provide unique thixotropiccharacteristics to sealant compositions. The sealants disclosed in thisbulletin are intended to be used in sealing material such as glass,metal or wood from the effects of the environment. These clear sealantsare said to adhere to a variety of substrates and may be painted ifdesired after the solvent components have evaporated. Means to provide100% non-volatile compounds are not disclosed, such compounds beingessential for sealing electrical connectors.

The use of KRATON thermoplastic rubbers in oil gels is presented inShell Chemical Company Technical Bulletin SC:1102-89 of April 1989entitled "KRATON Thermoplastic Rubbers in Oil Gels." This bulletinprovides information on the physical properties of KRATON G 1651 andKRATON G 1701x. The bulletin indicates that the KRATON G rubbercompounds may be used in a blend with polyethylene wax and processingoil to use as a waterproof sealant for telecommunications cable. Theneed for temperature resistance, insulation resistance and otherqualities required for sealed electrical connectors are not discussed.

SUMMARY OF THE INVENTION

Applicants have found that the deficiencies of the prior art can beovercome by sealant compositions which provide an unusual and difficultto obtain combination of properties. In particular, applicants havediscovered elastomeric compositions which are both slump and spewresistant while also being flowable over a moderately elevatedtemperature range. The term "flowable" is used to refer to theextrudability, injectability or pourability of the compositions of thepresent invention. The term "moderately elevated temperature range" isused herein to refer to the range of temperatures extending from aboutthe melt or softening point of the compositions upward to about 200° C.It should be noted that the present compositions are preferablysimultaneously slump and spew resistant and flowable through thismoderately elevated temperature range. Applicants have found that such acombination of features is highly beneficial from the standpoint of bothmanufacturing techniques and operability. The ability of the presentsealant compositions to resist slumping and spewing at the upper end ofits operating temperature range has obvious advantages in connectingdevices adapted for elevated temperature service, such as is frequentlyrequired in automotive applications. However, it is thoroughlyunexpected that such a property is capable of coexisting in a sealantwhich also has the processing advantage of being flowable at suchmoderately elevated temperatures. Applicants have achieved thissurprising result by providing compositions having a carefully selected,synergistic combination of components.

Because of the unique combination of properties described above, thecompositions of the present invention are especially well suited tofield repair of electrical connectors and connector housings. Theresistance of the compositions to spewing and slumping means that thecompositions remain in the connector even at the upper end of theoperating temperature range. Surprisingly, however, and despite theexcellent slump and spew resistance of the present compositions atmoderately elevated temperatures, the present compositions are flowableat such temperatures. These properties advantageously permit, forexample, the compositions to be injected by a syringe or similarapparatus into sealed connectors through the wire entry/exit holes ofthe connectors. The injectability of the present compositions eliminatesthe need to open a connector to add new material as required in manyprior art sealant compositions.

The preferred compositions of the present invention also have an abilityto bond, seal and insulate electrical contacts and connector housings,while simultaneously having a highly desirable balance of cohesivestrength and adhesive strength. Electrical connectors containing suchmaterials offer the possibility of being both effective and reusable.

Applicants have found that the adhesive strength of the preferredcompositions provides a strong temperature and water-resistant sealwhile the cohesive strength thereof ensures that the composition willremain in the connector when terminated wires or test probes areremoved. Furthermore, the substantial elastic memory and self-bonding ofthe preferred compositions result in substantially no voids being leftin a mass of the composition when the wire or test probe is removed.Thus, applicants have discovered compositions and connectors whicheliminate or substantially reduce the problems and disadvantagesassociated with the above-noted prior art materials and devices.

The present compositions preferably comprise a minor proportion byweight of elastomeric thermoplastic polymer and a major proportion byweight of extender for the polymer.

One important aspect of certain embodiments of the present compositionsresides in the particular extender used. In particular, it is highlypreferred that the extender comprise a primary extender for theelastomeric thermoplastic polymer and a secondary extender for theelastomeric thermoplastic polymer. It is especially preferred that theprimary extender comprise a low solvency latent extender and that thesecondary extender comprise a high solvency latent extender. These termsrefer to the relative ability of the extenders to swell, plasticize anddissolve the polymer in certain useful temperature regimes.

Another important aspect of certain embodiments of the presentcompositions resides in the particular thermoplastic elastomer used.Preferably the elastomeric thermoplastic polymer comprises a molecularcomposite of primary and secondary elastomeric thermoplastic polymers.For the purposes of convenience, the primary elastomeric thermoplasticpolymers of the present invention are sometimes referred to herein as"primarypolymers" and the secondary thermoplastic polymers are sometimesreferred to herein as "secondary polymers." As the terms are usedherein, "primary polymer" and "secondary polymer" are used in a relativesense. That is, these terms are used to identify polymeric materialshaving large differences in physical properties, and particularlypolymeric materials having large differences in melt viscositycharacteristics. In particular, the term "secondary polymer" is used toidentify those polymers which contribute at least to the substantialelastic memory, it is believed, by virtue of their high melt viscositywhen plasticized by the extenders. It will be understood that meltviscosity is directly dependent on and related to about the relativelythird power of the polymeric molecular weight which, it is believed,also critically determines the elastic memory. "Elastic memory" denotesthe ability of an artifact to return its original shape subsequent tothe release of a deforming stress. The polymers' molecular weight andelastic memory are characterized preferably by measuring their meltviscosity at a concentration of 5% by wt. in an extender, KAYDOL Oil, at300° F. By so characterizing, the "secondary polymers" have meltviscosities at least about 50 times greater than the same property ofthe primary polymer. According to expecially preferred embodiments, thisviscosity of the secondary polymer is at least about 100 times, and evenmore preferably about 200 times greater than the viscosity of theprimary polymer.

The primary polymers of the present invention preferably contribute toat least the following desirable properties of the polymer composite:thermal insulation; electrical insulation; cohesive strength; adhesivestrength; lubricating ability; resistance to temperature excursions andthe ability to resist slump or spew while maintaining flowability atmoderately elevated temperatures. The secondary polymers of the presentinvention preferably contribute to at least the substantial elasticmemory of the polymer composite. Although it is contemplated that theprimary polymer may comprise a diblock and/or a triblock copolymer, in apreferred embodiment the primary polymer consists of diblock copolymerand the secondary polymer consists of a triblock copolymer.

The relative proportions of the polymer and the extender are preferablyselected to provide the composition with substantial elastic memoryunder ambient and moderately elevated temperatures. According to otherpreferred embodiments, the compositions also possess: a high degree ofresistance to penetration and permeation by aqueous media; meltprocessability; substantially no stratification and/or componentseparation during temperature cycling; an ability to bond to solidobjects inserted into the composition; high cohesive strength; highadhesive strength to juxtaposed connector members; high electrical andthermal resistivity; high strain relief; high material inertness;lubricity and corrosion protection for associated connector members.

According to another aspect of the present invention the proportions ofthe components of the compositions are modified so that the compositionsmay be utilized as primers for treating the inside of an electricalconnector.

Applicants have also discovered advantageous methods for preparing thepresent sealant compositions. The present methods preferably requiremixing the organic elastomeric thermoplastic polymer and the extenderunder easily achieved time and temperature conditions sufficient toproduce an at least partially gelled organic polymer/extendercomposition, as evidenced by a substantial increase in the viscosity ofthe mixture. The present methods offer substantial advantages over themethods required to prepare prior art compositions. For example, theamount of energy required to produce sealant compositions according tothe present methods is small relative to prior art methods. This arises,at least in part, from elimination of the requirement for lengthy highshear mixing and/or extremely elevated temperature processing requiredby the prior methods.

The present invention also provides moisture and temperature resistantelectrical connectors for sealingly connecting transmission means. Suchconnectors include a connector body having a receiving means foraccepting and receiving a transmission means and a sealant compositiondisposed along or adjacent to the receiving means. The preferredconnectors also include means for inhibiting unwanted removal of thesealant composition from the connector body. According to especiallypreferred embodiments, the removal-inhibiting means also comprises meansfor wiping sealant from solid objects, such as said transmission means,upon removal of said objects from the connector body. According toanother preferred connector embodiment, the sealant composition disposedalong or adjacent to the receiving means of the connector body comprisesa sealant composition according to the present invention. Due in largepart to the beneficial characteristics and properties of the presentsealants, such connectors provide a highly moisture and temperatureresistant, readily repairable and/or modifiable electrical connection.

Methods for using the present sealants to establish a moistureresistant, readily repairable connection are also provided.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view partially exploded showing an array ofsilo-type rotary insulation displacement electrical connectors.

FIG. 2 is a perspective view of a connector body.

FIG. 3 is a partially cut away perspective view similar to that of FIG.2.

FIG. 4 is a side view of the connector body.

FIG. 5 is a top view of the connector body.

FIG. 6 is a back view of the connector body.

FIG. 7 is a stamped blank prior to being rolled into a connector body.

FIG. 8 is a perspective view of the terminating cap.

FIG. 8A is a perspective view of the terminating cap showing anembodiment including wiping means.

FIG. 9 is a top view of the terminating cap.

FIG. 10 is a side view of the terminating cap.

FIG. 11 is a bottom view of the terminating cap.

FIG. 12 is a longitudinal sectional perspective view of an uncrimpedferrule type pre-insulated crimpable insulation displacement connectorhaving sealant therein.

FIG. 13 is a cross-sectional view taken along line 13--13 of FIG. 12.

FIG. 14 is a view similar to FIG. 13 but showing the positions of thesealant and the parts after crimping.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS THE COMPOSITIONS

The present invention provides sealant compositions requiring twoessential components: elastomeric thermoplastic polymer, preferably anorganic polymer composite comprising diblock and triblock copolymers,and extender for the polymer.

An important aspect of the present invention is the requirement ofcertain embodiments that the extender comprise a primary and secondaryextender. Applicants have found that the secondary extender preferablycomprises, and more preferably consists of, a high solvency latentextender. As the term is used herein, "high solvency latent extender"refers to an extender which has substantially no capacity to form afunctional solution or gel of the elastomeric thermoplastic polymer attemperatures below about 40° C. while exhibiting a substantial swellingand dissolving capacity at temperatures above about 80° C. It ispreferred that the primary extender of the present invention comprise,and preferably consist of, a low solvency latent extender. As the termis used herein, a "low solvency latent extender" refers to an extenderwhich has no substantial capacity to form a functional solution or gelof the elastomeric thermoplastic polymer of the present invention belowabout 80° C. and has substantial dissolving capability only attemperatures above about 125° C. It should be understood that thisdissolving capability resides in the ability to solvate the polymermolecules and is also manifested in the relative plasticizing capabilityof the extenders.

Another important aspect of the present invention is the requirement ofcertain embodiments that the elastomeric, thermoplastic polymer comprisea composite of primary polymer and secondary polymer. The term "polymermolecular composite" is used herein to designate polymer compositionscomprising two or more polymeric compounds, preferably two or morepolymeric compounds mixed together in intertwined domains or ininterspersed domains. Thus, the term "polymer molecular composite"includes within its scope simple microscopically and sub-microscopicallycellular mixtures of two or more polymers, interpenetrating polymernetworks, graft copolymers, block copolymers and combinations of these.It is contemplated that one or more of the above-noted polymericconfigurations may be included in the structure of the present polymermolecular composites.

Importantly and desirably, the physical characteristics of the presentcompositions vary according to, among other conditions, the temperatureof the composition. As will be understood by those skilled in the art,sealant compositions must be operative over definite time andtemperature service ranges. That is, it is generally required that thesealant compositions maintain important specified characteristicssubstantially over an entire range of expected operating temperatures.Two such characteristics are that the compositions must be slump andspew resistant, even at the relatively high end of the operatingtemperature range. In order to maintain these characteristics at hightemperatures, many prior art sealants were stiff or rigid and difficultto process because of their high content of extender retainingcomponents. Applicants have discovered, however, that the sealants ofthe present invention are capable of being flowable and thus easilyprocessed at moderately elevated temperatures without sacrificing theoperating requirements of the sealant. Unless otherwise specificallyindicated, the term "flowable" refers to the ability of the compositionsto become fluent or viscid upon the application of shear stress orpressure.

As reported herein, the flowability of the present sealants is measuredby exposing about 50 grams of the sealant in the cylindrical chamber ofa standard hot melt gun to an extrusion pressure of about 30 psi atabout 163° C. for about 3 seconds and measuring the weight of sealantextruded from the gun. For purposes of defining flow conditions, theextrusion pressure is used as an expression of shear stress. Theflowability measurements presented herein are obtained using a hot-meltextrusion gun available from Fastening Technology, Inc. of Charlotte,N.C. sold under the trade name "PAM-Model 500-E." Such a gun is providedwith a 0.048 inch inside diameter type B nozzle. Such a nozzle isavailable from AMP Incorporated as Part Number 91H195.

Although the amount of flow may vary widely within the scope of thepresent invention, it is generally preferred that the presentcompositions exhibit at least about 0.1 g per 3 sec. (2 g/min.), andeven more preferably at least about 0.5 g per 3 sec. (10 g/min.) of flowat about 160° C.

As reported herein, the spew resistance (oil retention/extenderretention) of a sealant is measured according the protocol expressed inFederal Specification #321.1. Generally, measurement of spew resistancecomprises loading the defined weight of sealant into a conical containerhaving walls consisting of a stainless steel mesh as specified accordingto the federal standards. The amount of material which migrates from theconical container after the specified time period at the specifiedtemperature is a measure of the ability of the present sealants toresist spewing or exudation of the extender portions thereof. The spewresistance is reported herein as percent extender retention and isdetermined by dividing the sealant weight contained in the conicalcontainer after the test by the weight of sealant at the start of thetest. Although the amount of spew resistance may vary widely within thescope of the present invention, it is generally preferred that thepresent compositions exhibit a spew resistance of at least about 99%extender retention at about 80° C., and even more preferably at leastabout 99.5% at about 80° C.

As reported herein, slump resistance is measured by a modified versionof ASTM Test Method D2202. In general, the unmodified ASTM Test D2202requires formation of a cylindrical cavity in a metal sheet or slab bywithdrawing a mating cylindrical body or piston from the slab. Thiscavity is then filled with the material to be measured. According to theunmodified version of the test method, the slab is placed in a verticalposition, and the piston is then driven forward to occupy one-half ofthe original cavity space, thus causing about one-half of the originaltest material volume to be displaced past the surface of the slab. Uponheating to the test temperature, the amount of downward droop ormovement of the displaced material is measured. According to themodification utilized herein, the piston is driven forward to occupy allof the original cavity volume such that face of the piston is flush withthe surface of the slab. As a result, the entire body of sealant isdisplaced from the cavity. In this way, the modified ASTM Test D2202measures not only the slump resistance of the sealant material, but alsoits adhesive properties. Although the amount of slump resistance mayalso vary widely within the scope of the present invention, it isgenerally preferred that the present compositions exhibit a slumpresistance of less than about 0.5 in. of slump, and even more preferablyless than about 0.2 in. of slump at about 80° C.

Although the operating temperature range of any particular sealant willdepend upon numerous factors regarding the expected application, thepresent sealant compositions preferably have an operating temperaturerange of from about -40° C. to about 125° C. At relatively lowtemperatures, for example, from about -20° C. to about +80° C., thepresent compositions are preferably especially soft, tacky and rubbery.At relatively elevated temperatures, for example above about 125° C. toabout 150° C., the compositions are flowable while substantiallyresisting spew and slump, thus enabling the material to be more easilyhandled during the process of incorporating the sealant into theconnector.

For temperatures of from about -40° C. to about +80° C., the presentcompositions preferably exhibit an elastic memory of at least about 100to 150%, and even more preferably at least about 200 to 300%. As theterm is used herein, elastic memory refers to the ability of acomposition to return to about its original configuration after beingsubjected to the designated extent of elongation. The high degree ofelastic memory exhibited by the present compositions provides sealantswith a highly advantageous "self-repairing" property. That is, thepresent sealants will deform to accommodate stress exerted by, forexample, the insertion of an electrical wire into a mass of the sealant.Upon removal of the wire and hence the accompanying stress, theexceptional elastic memory of the present compositions causes the massof sealant to return to substantially its original shape and thereby tosubstantially fill the void resulting from the removal of the wire. Thisself-repairing quality of the present sealants is one important aspectof the present invention. Another important aspect is the ability toself-heal while self-repairing. In addition, the sealants of the presentinvention maintain their bond with and move with the wires when flexedfunctionally maintaining the integrity of the seal.

For temperatures of from about -40° C. to about +80° C., the presentcompositions preferably have an adhesive strength of from about 2 g toabout 12 g, and even more preferably of from about 5 g to about 12 g.Applicants have found that the adhesive strength of the present sealantcompositions is related to the ability of the compositions to provide asealed electrical connection, and that the use of high adhesive strengthcompositions will generally produce high quality electrically insulatedconnections. As the term is used herein, "adhesive strength" refers tothe amount of force, as measured by gram weight under standard gravityconditions, required to remove an 181/2 gauge PVC covered electricalwire from a mass of sealant contained in a standard terminal block silo.The measurement of adhesive strength is preferably made by insertingabout 1/4 inch of the PVC covered wire into the sealant-filled terminalblock silo and measuring the amount of force required to remove same. Asused herein, the term "standard terminal block silo" refers to asubstantially cylindrical connector housing having a height of about 11mm, an inner diameter of about 14 mm, and a free volume of about 1.6 ml,with a substantially circular access opening of about 5 mm diameter in asidewall thereof.

The excellent ability of the present compositions to effectively sealelectrical connections is also due, at least in part, to the combinationof high elastic memory and high adhesive strength exhibited by thecompositions disclosed herein. In particular, the high wetting andconformability and elastic memory of the present compositions result ina material which strongly captivates objects, such as electrical wires,inserted into a mass thereof. This feature, along with the highinsulation resistance and the strong tendency of the presentcompositions to adhere to such objects, produce an effective andlong-lived isolation of the electrical connections from the surroundingenvironment.

The present compositions also preferably have a high cohesive strength.For the purposes of convenience and illustration, cohesive strength ismeasured herein by determining the gram weight of sealant which isremoved from a standard connector silo when an 181/2 gauge PVC coveredsteel electrical wire is removed from a mass of sealant contained in astandard terminal block silo. The measurement of cohesive strength ispreferably made by inserting about 1/4 inch of the PVC covered wire intoa standard sealant-filled terminal block silo and measuring the amountof sealant which is removed from the silo when the wire is removed. Thecohesive strength is therefore used herein to refer to the tendency ofsealant to remain as a unit mass in the connector silo when the 181/2gauge PVC covered electrical wire is withdrawn, as will typically occurduring repair and/or replacement of electrical connectors. Fortemperatures of from about -40° C. to about +80° C., the presentcompositions preferably have a cohesive strength as measured by sealantremoval of no greater than about 0.2 g, and even more preferably nogreater than about 0.04 g.

Another important aspect of certain embodiments of the present inventionresides in sealant compositions having both high adhesive strength andhigh cohesive strength. In particular, it will be generally understoodby those skilled in the art that a sealant composition possessing onebut not the other of these characteristics will not fully satisfy theobjects of the present invention. For example, the use in an electricalconnector of a sealant which is high in adhesive strength but low incohesive strength will result in a large amount of sealant beingwithdrawn from the connection site during repair or replacement of theconnection. On the other hand, the use in an electrical connector of asealant which possesses high cohesive strength but low adhesionproperties will likely produce a poor quality electrical connectionseal. Accordingly, the present sealant compositions preferably have anadhesive strength of from about 2 g to about 12 g and a cohesivestrength as measured by removal weight of from about 0 g to about 0.2 gat temperatures of about -40° C. to about +80° C. Even more preferably,the present compositions have an adhesive strength of from about 5 g toabout 12 g and a cohesive strength of from about 0 g to about 0.02 g attemperatures of from about -30° C. to about +60° C.

Although applicants do not wish to be necessarily bound by or limited toany particular theory, it is believed that the ability of the preferredcompositions to exhibit the above-noted combination of beneficialproperties is due, at least in part, to the physical and chemicalrelationship between the components of the present composition. Inparticular, the combination of an elastomeric thermoplastic polymer andan extender according to the present invention is believed to contributeto the beneficial properties of the compositions. For example, it iscontemplated that the mixture of the diblock and triblock elastomericthermoplastic polymers according to preferred embodiments comprises aninterpenetrating polymer network CIPN). It is believed that the presenceof such a polymer network, especially in the presence of optionalinorganic gelants, maintains the extender portion of the presentcompositions in a highly stable dispersed, colloidal, gelled and/ornetworked (reticulated) or fused state in which exudation or spewing ofthe extender is strongly inhibited. In addition, it is believed thatsuch a configuration contributes to the high cohesive strength of thepresent compositions.

In certain embodiments of the present invention, the extender hereof mayitself include polymer components, as explained more fully hereinafter.It is contemplated that in such embodiments, the extender mayparticipate in and be part of the IPN of the present invention, therebyfurther enhancing the adhesive strength and exudation resistance of thepresent compositions.

As those skilled in the art are aware, interpenetrating polymer networks(IPNs) are a special class of polymer molecular blends in which two ormore polymers exist in a highly networked structure. As the term is usedherein, interpenetrating polymer network refers to true IPNs, apparentIPNs, semi-IPNs, and combinations and hybrids of these. As the term isused herein, a "true IPN" refers to those polymer network domains inwhich two or more polymer systems are crosslinked within their owndomains but not to each other. In true IPN's, the distinct polymersystems form crosslinked network domains that interpenetrate each other.As the term is used herein, a semi-IPN refers to those polymer networksin which one polymer system exists in an uncrosslinked state butinterpenetrates a second polymer system which is crosslinked and has itsown domain.

The term "physical IPN" as used herein refers to co-continuousinterpenetrating phases in which none of the polymers is chemicallycrosslinked but which is nevertheless stabilized by physical polymercrosslinks which may be provided, for example, by the styrene end blocksof styrene-ethylene-butylene-styrene block copolymers. As explained morefully hereinafter, it is believed that the preferred polymer compositesof the present invention are believed to comprise a polymer networkstructure having characteristics of a physical IPN. Additionally, thepreferred polymer composite properties may be enhanced by inorganicnetwork formers such as "fumed" silica, i.e. amorphous silica withparticle sizes as defined by surface areas of about 100 to 300 sq.m./g.

It is contemplated that the preferred IPNs of the present invention maybe formed using a variety of techniques and all such techniques arewithin the scope of the present invention.

While the mechanisms which create the observed properties andcharacteristics of the present compositions are not to be construed asfully explained by present technology, it is believed that the preferredembodiments of the present invention comprise compositions in the formof a thermally reversible polymeric gel state. In particular, thepresent compositions exhibit characteristics which are sometimesassociated with thermally reversible polymeric gels. For example,reversible polymeric gels are elastomeric and non-flowable under certainconditions but are converted to a liquid-like, flowable state when thecondition of the gel is altered, for example, by increasing temperature.Thus, it is believed that the present compositions, especially when thecomponents are in the preferred ranges described below, are in the formof a reversible polymeric gel in which the extender is contained as acolloidal dispersion or solution of liquid in a polymer compositecomprising effectively, i.e. functionally, crosslinked thermoplasticelastomer and other polymers.

A. Elastomeric Thermoplastic Polymer

As the term is used herein, organic "thermoplastic elastomers" are thoseorganic polymers which possess, or which may be plasticized to possess,elastomeric properties under a first set of temperature conditions andwhich are flowable under a second set of temperature conditions. It isgenerally preferred that the present elastoplastic polymers areelastomeric at temperatures of from about -40° C. to at least about+150° C., and that the polymers become flowable yet thermally stable attemperatures of from about +150° C. to at least about +200° C. in theirneat uncompounded state. It is generally preferred that at ambienttemperatures the thermoplastic elastomer used in the present polymercomposites is sufficiently rigid to retain its general shape anddimension and sufficiently flexible to exhibit substantial recovery uponstretching. As used herein, the term "organic polymer" refers topolymeric materials in which at least a portion of the polymer backboneis comprised of carbon atoms.

According to specially preferred embodiments, the elastomericthermoplastic polymer comprises a composite of a primary polymer and asecondary polymer. While it is contemplated that all such composites areadaptable for use according to the present invention, compositescomprising a physical mixture of block copolymers has been found to beespecially useful and is preferred. It is even more preferred that thepresent compositions comprise an elastomeric thermoplastic polymercomposite in the form of a physical IPN comprising block copolymers, andeven more preferably comprising diblock and triblock copolymers.

It is also contemplated that the relative proportions of primary andsecondary polymers may vary over a wide range within the scope of theinvention. Such variation will depend, for example, on the particulartype of connector in which the sealant composition will be used and thecontemplated operating environment for the connector. In general,however, applicants have found that the elastomeric thermoplasticpolymer of the present invention preferably comprises a physical IPN,and even more preferably, an IPN comprising a major proportion by weightof primary polymer and a minor proportion by weight of secondarypolymer. It is especially preferred that the weight ratio of secondarypolymer to primary polymer be smaller than about 1:5, and morepreferably no greater than about 1:10. Applications have also found thatit is generally highly desirable for the present polymer composites tocomprise at least 0.4% by weight of secondary polymer. Accordingly, thepolymer composites of the present invention preferably have a secondarypolymer:primary polymer weight ratio of no smaller than about 1:20.Without intending to be bound by or limited to any particular theory, itis believed that compositions containing smaller than the above-notedpolymer ratio will not possess certain of the desirable and beneficialproperties exhibited by the present compositions. For example, theability of the sealant compositions to remain within the connectorduring normal operating conditions have been found to deteriorate incertain embodiments when the above-noted lower limit of secondarypolymer is not satisfied.

Numerous block copolymers exhibiting elastoplastic properties are known,readily available and within the broad scope of the present invention.The block copolymers used in the present polymer composites preferablycontain at least one elastomeric block and one non-elastomeric block.Such block copolymers are referred to generally as A-B diblockcopolymers wherein A represents a block of non-elastomeric polymer and Brepresents a block of elastomeric polymer connected thereto. As theterms are used herein, a block of elastomeric polymer refers to apolymer which can be stretched at about room temperature to at leasttwice its original length and, after having been stretched and thestress removed, returns with force to approximately its original lengthin a short time period. In contrast, non-elastomeric blocks according tothe present invention do not exhibit this characteristic.

The elastomeric B blocks of the present block copolymers are preferablyselected from the group consisting of non-aromatic polyolefins,polyesters, polyethers and combinations of these, with non-aromaticpolyolefins being preferred. Polyolefins formed from conjugated dienes,such as butadiene and isoprene, and the partially or fully hydrogenatedforms thereof and polyolefins formed from propylene, ethylene, buteneand combinations thereof, are especially preferred. It is contemplatedthat block copolymers having a large variety of chemical constitutionsare adaptable for use according to the present invention, since theelastoplastic characteristics are believed not to depend on any specificchemical constitution, but rather upon the polymeric architecture ofeach of the polymer blocks. Thus, block copolymers having linear, radialor branch structures are generally within the scope of the presentinvention.

The non-elastomeric A blocks are preferably selected from the groupconsisting of poly (alkenyl arenes), polyurethanes and combinations ofthese, with poly (alkenyl arenes) being preferred. The non-elastomeric Ablocks may comprise homopolymers or copolymers but preferably arehomopolymers prepared from alkenyl arenes, such as styrene, methylstyrene, vinyl xylene, ethylene vinyl xylene, isopropyl styrene, vinylnaphthalene and the like, with monoalkenyl monocyclic arenes, such asstyrenes, being preferred.

Especially preferred block copolymers are diblock and triblockcopolymers. The diblock copolymers have the general configuration A-Bwith about one A block for each B block, and the triblock copolymershave the general configuration A-B-A wherein the polymer predominantlycontains A blocks at the end of each B block. It is especially preferredthat each A block is "hard" crystalline, semi-crystalline or glassypolymer end block segment, such as polystyrene and that B is a "soft"elastomeric polymer mid-block segment, preferably comprised of anon-aromatic polyolefin, such as polyethylene, polypropylene,polybutylene and/or combinations of these. The non-aromatic polyolefinsegments of such diblock and triblock copolymers are generally poorlycompatible with the "hard" end-block and form a microscopic two-phasemorphology consisting of domains of glassy end blocks interconnected byflexible mid-block chains. The physical elastomeric network structure ofsuch diblock and triblock copolymers is reversible, and heating thepolymer above the end-block glass transition temperature willtemporarily disrupt the structure, which can be restored by lowering thetemperature.

Triblock copolymers as described herein can be prepared according to anumber of well-known techniques, including the methods described in U.S.Pat. No. 3,485,787--Haefele, which is incorporated herein by reference.

It is contemplated that the elastomeric thermoplastic polymer of thepresent invention may also comprise thermoplastic polyurethaneelastomers and thermoplastic polyester/polyether elastomers. In general,such polyurethanes are addition polymers obtained from the chemicalreactions of isocyanates. Isocyanates commonly used in the formation ofpolyurethanes are toluene diisocyanate, diphenyl methane diisocyanateisophorone diisocyanate and polymeric diisocyanates (PMDI), polymersderived from the condensation of aniline with formaldehyde. Polyurethaneand polyester/polyether thermoplastic elastomers are alternating blockcopolymers having segments of the "hard," highly polar or crystallizingmaterial, such as polyurethane, linked by "soft" segments of amorphousmaterials, such as polyester which are rubber-like at normaltemperatures.

The present compositions preferably comprise a minor proportion byweight of organic thermoplastic elastomer. It is especially preferredthat the sealants of the present invention comprise less than abouttwenty percent, and even more preferably less than about ten percent, byweight of organic thermoplastic elastomer.

B. The Extender

Applicants have found that the extenders of the present invention imparthighly beneficial and advantageous characteristics to the sealantcompositions and to the methods by which such compositions are prepared.In particular, extenders comprising a combination of both primary andsecondary extenders and contribute to the surprising and unexpectedrheological properties of the present compositions.

For the purposes of convenience but not by way of limitation, theextenders of the present invention can generally be classified as eitherprimary or secondary extender. When the polymer-to-extender attractionis strong, the extender has high compatibility with and high solvencyfor the thermoplastic elastomer and is said to be a secondary extender.Where the polymer-to-extender attraction is relatively weak, theextender is of the primary type. Primary extenders function as spacersbetween polymer chains but, according to prior processes, could notgenerally be used exclusively of secondary extenders because of limitedcompatibility. This lack of compatibility was frequently manifested inprior materials by a tendency of the extender to exude or spew from thecomposition under conditions of elevated, cyclical temperature and/orstress.

In the present compositions, however, the tendency of the extender toexude or spew is greatly reduced or eliminated. Applicants believe thatthis advantage is provided, at least in part, by the IPN type structureof the preferred polymer composites of the present invention. Inaddition to the benefits provided by the elastomeric thermoplasticpolymer, the present compositions also benefit from the use of thepreferred secondary extenders. In particular, applicants have found thatit is highly preferred for the secondary extenders to comprise highsolvency latent extenders. The incorporation of such high solvencylatent extenders in the present compositions provides the advantageousproperties associated with primary extenders without the disadvantagestypically encountered by the use of such extenders in prior artcompositions. In particular, applicants have found that the hightemperature solvating power of high solvency latent extenders tends toreduce spewing or extruding associated with other primary extenders.Moreover, the increased high temperature solubility is also believed toenhance the flowability of the compositions at increased temperaturesand to enhance the formation of the gel network structure. On the otherhand, the lack of solubility at relatively low temperatures allows theextender material to be maintained in a gel-type matrix withoutdetracting from the elastomeric properties of the sealant. In addition,the low solvency latent extender is beneficial in that it tends toreduce the stiffness and increase the softness of the composition underconditions of use. Moreover, the presence of the low solvency latentextender in the composition contributes to the ability of the preferredcompositions to "wet-out" and to be affined to the components of theelectrical connectors, thereby providing excellent sealing properties.

In general, the extender of the present invention generally performs oneor more of several functions, and accordingly a large number ofavailable extenders may be utilized, provided the requirements describedherein are satisfied. For example, particular extenders may be chosen toincrease or decrease the workability, flexibility and/or distensibilityof the thermoplastic elastomers of the present invention, depending uponthe particular application. As is well known to those skilled in theart, extenders are generally high boiling, chemically and thermallystable organic liquids, low-melting solids or semi-solids.

The extender is preferably present in a large weight percentage of thecomposition in order to reduce the overall cost of the compositionswithout negatively affecting the beneficial properties thereof. With theguidance provided herein, it is expected that one skilled in the artwill be capable of selecting the extender needed for any particularapplication without undue experimentation.

An important aspect of the present invention resides in the ability ofthe extender to fluidize, solvate, gel and/or fuse with thethermoplastic elastomer and/or the inorganic cross-linked polymer. Inthis regard, it is believed that the extenders of the present inventionachieve the desired result through external plasticization of thepresent compositions. That is, it is believed that the present extendersinteract primarily physically and not chemically with the components ofthe above described polymer composite to reduce the mutual attractiveforces between polymer chains in the sealant compositions. Accordingly,while the compositions of the present invention may include a certainamount of internal plasticization, such as, for example,copolymerization of the extender with the polymer blend, this is notbelieved to be necessary or desirable for operation of the presentinvention. Thus, the extenders of the present invention preferably serveto aid in the processing characteristics of the present compositions toimpart flexibility, elongation and toughness to the compositions withoutreacting chemically therewith. It is generally preferred that thepresent extenders are relatively viscous materials having a pour pointof about 0° C. or less, and even more preferably from about -30° C. toabout 0° C.

It is contemplated that numerous known and available materials may beused as primary and secondary extenders according to the presentinvention. The particular primary and secondary extenders selected willdepend upon factors such as expected conditions of use, expense andother components in the composition. It is contemplated that thoseskilled in the art will be able to select appropriate primary andsecondary extenders for any particular application in view of theinformation provided herein. For compositions in which the elastomericthermoplastic polymer comprises a combination of diblock and triblockcopolymer, it is preferred that the secondary extender be selected fromthe group consisting of naphthenic oils, white oils and terpenoidhydrocarbons and that the primary extender be selected from the groupconsisting of polybutadiene, polybutene, polybutylene, hydrocarbonresins, atactic polypropylene, branched polyethylene and low molecularweight styrenic polymers. The extenders of the present invention maycomprise numerous and varied combinations of particular extendersprovided that the requirements described above are satisfied.

The extender of the present invention is preferably selected from thegroup comprising one or more of the following: aliphatic hydrocarbons,such as aliphatic mineral oil; aromatic hydrocarbons, such as aromaticmineral oil; C1-C6 non-aromatic polyolefins, such as polybutene; estercompounds, such as monomeric phthalate esters, dibasic acid esters,trimellitates, phosphate esters and polyesters; glycol benzoates;citrates; isophthalates; chlorinated hydrocarbons; sebacates andmixtures and combinations of the these.

Applicants have found that compositions with highly preferred propertiesare obtained when the primary extender comprises, preferably in majorproportion, C1-C4 polyolefin, with C4 polyolefin being preferred andpolybutene and polybutadiene even more preferred and polyisobutene beingeven still more preferred. Applicants have found that primary extenderscomprising such polyolefins, especially primary extenders comprising atleast about 90 percent by weight of low molecular weight highlyparaffinic polybutenes and polyisobutylenes, are capable of enhancingthe adhesive properties of the sealant, thus contributing to the abilityof the composition to seal electrical contacts from corrosiveenvironments. Such materials are available from Amoco Chemical under thetrademark INDOPOL H-100 and from Exxon under the trademark VISTANEXLM-MS. With respect to polybutene and polyisobutylene extenders, theterm low molecular weight is used herein to refer to such materialshaving a viscosity average molecular weight (Staudinger) of about 8700to about 11700. Molecular weights of from about 8700 to about 10000 areespecially preferred for applications requiring strong adhesionstrength. It is also preferred that the C1-C4 polyolefins have a pourpoint of about 32° F. or less, and even more preferably from about 5° F.to about 32° F. Such a polybutene extender is available from Amoco underthe designation INDOPOL H-100.

According to preferred embodiments of the present invention, thesecondary extender comprises mineral oil. Without being bound by orlimited to any particular theory, it is believed that the presence ofmineral oil as the secondary extender contributes to the wetting abilityof the composition. The mineral oils of the present invention arepreferably relatively high viscosity mineral oils having an SUS at 100°F. of from about 300 to about 600, a specific gravity at about 25° C. ofabout 0.85 to about 0.89, and a pour point of from about -25° C. toabout 0° C. A preferred material is available from the SonnebornCompany, a division of Witco Corp., under the designation KAYDOL.Mineral oil sold under the trade name BRITOL 55T from Malcolm Nicol &Co., Inc., Lindhurst, New Jersey, is also a preferred mineral oil foruse in the extender of the present invention.

Applicants have found that compositions with highly preferred propertiesare obtained when the extender comprises, preferably in majorproportion, a mixture of secondary and primary extenders, andparticularly a mixture of secondary extender comprising aliphatichydrocarbon and a primary extender comprising C4 polyolefin, withmineral oil being the preferred hydrocarbon and polyisobutene being thepreferred C4 polyolefin. Applicants have found that extenders comprisingsuch mixtures, especially extenders comprising at least about 85 percentby weight of such mixtures, are capable of at once providingthermoplastic elastomers with an excellent ability to wet out objectsbrought into contact with the composition, excellent adhesive strengthand excellent cohesive strength. Without being bound by or limited toany particular theory, it is believed that the presence of the secondaryextender mineral oil in the extender mixture contributes to the wettingability of the composition while the primary extender polyisobutenecontributes to the adhesive and cohesive strength. It is preferred thatthe extenders have a primary:secondary polyolefin weight ratio of fromabout 20:80 to about 70:30, with about 40:60 to about 60:40 being evenmore preferred. These ratios are also preferred for extenders in whichthe primary extender is a low solvency latent extender and the secondaryextender is a high solvency latent extender. According to a preferredembodiment of the present invention, the extender comprises about 45parts by weight of mineral oil and about 45 parts by weight ofpolyisobutene.

It is contemplated that the amount of extender used can vary widely,depending upon such factors as the expected use of the composition, thecharacteristics of the elastomeric thermoplastic, and the like. Animportant advantage of the present compositions, however, is the abilityto incorporate very large concentrations of extender in the compositionwithout negatively affecting the beneficial properties thereof. Thus, itis highly preferred that the extender:polymer composite weight ratio ofthe composition is from about 99.5:0.5 to about 85:15, and even morepreferably from about 93:7 to about 88:12. For the purposes ofdetermining this ratio, the composite weight is the weight of thediblock and triblock organic thermoplastic elastomeric polymerstogether.

C. Other Components

It is contemplated that the present sealant compositions may includeother components which provide other desirable properties to the sealantcomposition without detracting from the beneficial characteristicsmentioned above.

It is contemplated that corrosion inhibitors, preferably minor amountsthereof, may be included in the present sealant compositions to enhancethe integrity of the connection. Such inhibitors are available in widevariety of types and grades and from a wide variety of sources, and allsuch inhibitors are within the scope of the present invention. Highmolecular weight synthetic barium sulfonate is a corrosion-inhibitingmaterial available under the trade name NA-SUL BSN from the R. T.Vanderbilt Company in Norwalk, Connecticut. Chemisorption components,preferably benzotriazole, are available from PMC Incorporated under thetrade designation COBRATEC 99 and may be incorporated in minor amountsin the present compositions.

Antioxidants and thermal stabilizers may also be incorporated,preferably in minor amounts, in the present sealing compositions.Preferred antioxidant/thermal stabilizers are hydroxyhydrocinnamatebased compounds available from Ciba-Geigy Corporation, Hawthorne, NewYork, under the trade designation, IRGANOX, as described in Ciba-Geigybulletin "IRGANOX® 1010, Antioxidant and Thermal Stabilizer" (1990). Amixture of IRGANOX 1010 and IRGANOX 1035 is preferred. Otherantioxidants are available from the American Cyanamid Company, Wayne,New Jersey, under the trade designation "CYANOX." Particularly preferredCYANOX compounds are CYANOX 1790 and CYANOX LTDP.

The present compositions may also contain light and heat stabilizingcomponents, preferably in minor amounts. One such stabilizer isavailable from the American Cyanamid Company under the trade designation"CYASORB." Especially preferred CYASORB materials are CYASORBUV3346.

The present compositions may also contain minor amounts of fungicidesand/or antimicrobials. Such materials are available from MortonInternational Specialty Chemicals Group, Danvers, Mass., under the tradedesignation "VINYZENE" and from Calgon Corporation under the tradedesignation "METASOL TX-100." In certain preferred embodiments of thepresent invention, the sealant compositions may also include athickening agent such as silica and preferably fumed silica. Silica mayalso serve to act as a temperature stabilizing agent. Such materials areavailable as fully hydrophobized surface treated amorphous silicas fromCabot Corporation under the designations "CAB-O-SIL," such as "CAB-O-SILTS-610" and "CAB-O-SIL TS-530" and from Degussa Corporation under thedesignation "AEROSIL R-974." Hydrophilic amorphous silicas are availablefrom Cabot Corporation under the trade designation "CAB-O-SIL M-5" andfrom Degussa Corporation under the trade designation "AEROSIL 200."Incorporation of minor amounts, preferably less than about 8% by weight,of silica into the present compositions tends to favorably control therheology of the sealant and to enhance the cohesive strength thereof.

The present compositions may optionally include a polymer compositewhich comprises a crosslinked polymer, preferably an inorganiccrosslinked polymer, and even more preferably a crosslinkedsilicon-based polymer. As the term is used herein, inorganic polymerrefers to polymers having inorganic elements making up at least aportion of the backbone of the polymer chain. With respect to thepreferred silicon-based polymers of the present invention, silicon atomscontribute to the chemically inert and environmentally benign characterof the polymer and are present either alone in the backbone or withatoms of oxygen, carbon, nitrogen, etc. in the backbone. Thus, the termsilicon-based polymer is used herein to refer to a wide range of siliconcontaining polymers, including polysilanes, polysiloxanes,polysilalkylenes and polysilarylenes, with polysiloxanes beingpreferred. Siloxane polymers are commonly referred to as siliconepolymers and will frequently be referred to herein as such.

The siloxane type polymers of the present invention preferably have thegeneral structure shown below and may be prepared, for example, by ringopening polymerization of a trimer or a tetramer: ##STR1## where R₁ andR₂ are the same or different and are H, OH, alkyl, alkenyl, aryl oraryl-alkyl and n is the degree of polymerization.

The preferred silicon-based polymer of the present invention is at leastpartially crosslinked. A large variety of crosslinked silicon-basedpolymers and precursors therefor are available and all such polymers arewithin the scope of the present invention. For example, crosslinkedsilicon-based polymers may be formed by reacting functionally terminatedsiloxane polymer chains with a polyfunctional end linker. It ispreferred that the crosslinked polymers of the present inventioncomprise, preferably in major proportion, crosslinked silicone polymersformed by platinum catalyzed vinyl-addition reactions between hydride-and vinyl-functionalized silicone polymers.

For compositions which contain the optional crosslinked inorganicsilicon-based polymer, it is especially preferred that silicon-basedpolymer is crosslinked in the presence of the thermoplastic elastomer ofthe present invention. As the term is used herein, a polymer crosslinkedin the presence of another polymer refers to chemical crosslinkingreactions in which the reactants are intimately intermixed with theother polymer or precursors for the other polymer as the reaction takesplace. It is preferred that such intimate mixing during the crosslinkingreaction results in the formation of an interpenetrating polymernetwork.

According to certain embodiments, the present compositions preferablycomprise a minor proportion by weight of inorganic crosslinked polymer.It is especially preferred that the sealants of the present inventioncomprise less than about 35 percent, and even more preferably less thanabout 25 percent, by weight of inorganic crosslinked polymer. Theorganic thermoplastic elastomeric polymer and the inorganic crosslinkedpolymer may together comprise less than about 20 percent, and even morepreferably less than about 15 percent, by weight of the composition.Such embodiments are not only advantageous from an economic point ofview, they possess surprisingly beneficial results.

The details of the preferred methods for forming the polymer compositesof the present invention are described more fully hereinafter.

I. THE CONNECTORS

It is contemplated that the desirable properties of the presentcompositions will be advantageous in a wide variety of electricalconnectors, and all such connectors containing the present compositionsare within the scope of the present invention. Moreover, the presentinvention also provides connectors which eliminate or substantiallyreduce the tendency of sealant compositions used therewith to migrate orooze from the connector. Connectors according to such embodiments areadaptable for use with a wide variety of sealant compositions, includingthose of the type disclosed in the prior art as well as those of thepresent invention.

The present invention provides moisture proof, temperature resistant andnoise resistant electrical connectors for sealingly connectingtransmission means therein. The preferred connectors of the presentinvention comprise a connector body having a terminal means foraccepting and electrically connecting to the transmission means insertedappropriately into the connector body and a sealant composition disposedalong or adjacent to the terminal means of the connector body. In orderto maximize the sealing ability of the connector, the connector bodypreferably comprises a substantially closed housing or container, andthe container is preferably substantially filled with sealantcomposition. In such embodiments, the container includes access meansfor allowing entry of the transmission means into the connector body forcontact with the terminal means and the sealant composition. The accessmeans preferably comprises said container having an access openingtherein.

It will be appreciated by those skilled in the art that, under certainconditions, many of the prior sealant compositions contained in such acontainer tended to migrate or ooze from the connector body through theaccess means. While the sealant compositions of the present inventionpossess properties and characteristics which substantially reduce oreliminate such migration, it is preferred that the present connectorsinclude wiper means substantially covering said access opening forallowing withdrawal of the transmission means from the connecter whileretaining said sealant within said housing. The provision of wiper meansaccording to the present invention advantageously facilitates repair andreplacement of electrical connections. In particular, the wiper meansprovides ingress and egress to the transmission means whilesimultaneously substantially reducing the migration of sealantcomposition, even relatively flowable and migratory sealants, from theconnector.

It is preferred that the wiper means of the present invention comprise aresilient thin membrane adhered to the connector body and covering theaccess opening. Such resilient membrane also preferably includes anaccess opening therein for permitting entry of the transmission meansinto the connector body wherein the dimension between at least two edgesof said resilient membrane access opening are less than, and preferablysubstantially less than, the cross-section of said transmission means.In this way, the edges of such opening provide means for wiping sealantcomposition from the outer surface of the transmission means when thetransmission means is withdrawn from the connector body, as frequentlyis required during repair operations. According to certain embodimentsit is preferred that the smallest dimension of the wiper means accessopening is at least about 0.2 times the smallest cross-sectionaldimension of the transmission means, and even more preferably about 0.1times the smallest dimension of the connector body access opening.

The resilient membrane used according to the preferred embodiments ofthe present invention should provide sufficient flexibility to allow thetransmission means to be readily inserted and withdrawn from theconnector body while simultaneously possessing sufficient rigidity toovercome any adhesion forces between the sealant composition and thetransmission means, thereby wiping sealant means from the transmissionmeans during the withdrawal process. While it is contemplated that alarge number of materials in varying thicknesses and sizes are adaptablefor use according to the present invention, thin polyurethane filmshaving a thickness of from about 1 mm to about 5 mm are preferred.

It is also contemplated that the particular shape and configuration ofthe access opening in the wiper means will vary depending upon the typeof sealant used and particular applications involved. For example, theaccess opening may comprise a simple slit in the resilient film, a starpattern of slots or an aperture of circular, square or triangular shape.These and other access openings are all within the scope of the presentinvention.

A. First Embodiment

A first preferred embodiment of the present invention will now bedescribed in connection with FIGS. 1-11. Connectors of the general typeillustrated in these figures are described in U.S. Pat. Nos.4,705,340--Luce and 5,006,077, each of which is incorporated herein byreference and assigned to the assignee of the present invention. Theseconnectors are available from AMP Incorporated under the tradedesignation "Quiet Front."

Referring now to FIG. 1, a terminal block 100 having a plurality ofsilo-type rotary insulation displacement electrical connectors 10 isillustrated. The connector housings 10 house a terminal, referred togenerally as 10A in FIGS. 2 and 3, substantially closed at the top bymating rotatable cap 50 and at the bottom by, for example, the base 94of terminal block 92. The terminal 10A is substantiallycylindrically-shaped and has a upper insulation displacement portion 8and a lower insulation displacement portion 6. In operation, theterminal is substantially completely filled with sealant, preferably thesealant composition of the present invention. The terminal parts arepreferably stamped from a metal having good electrical conductingqualities. These conductive qualities are desirable because transmissionmeans, preferably two signal-carrying wires 90, are terminated to theterminals and the signal is carried through the terminal.

Referring now to FIG. 7, a preferred method of forming the terminal isdisclosed. In particular, the terminal is stamped from a blank 2 havingtop bearing surfaces 34 and 40, forward surface 44, tab 45 on forwardsurface 44, bottom surface 42 and a recessed surface 48. Blank 2includes an inner small wire opening 18A in tab 45, the opening 18Abeing in transition with an inner small wire receiving slot 20A definedby sheared surfaces 21A. Blank 2 also includes an inner large wirereceiving opening 12A in transition with an inner large wire receivingslot 14A defined by sheared surfaces 15A. Strain relief slots 16A arelocated above and below the large wire opening 12A and large wire slot14A. The blank 2 includes outer small wire receiving opening 18B intransition with outer small wire receiving slot 20B defined by shearedsurfaces 21B, and strain relief slots 22B above and below opening 18Band slot 20B. The blank 2 includes an outer large wire receiving opening12B in transition with an outer large wire receiving slot 14B defined bysheared surfaces 15B. Strain relief slots 16B are located above andbelow the opening 12B and slot 14B.

The terminal 10A is formed by rolling the stamped blank of FIG. 7 intocylindrical shape, the cylinder comprising a spiraled double wallthickness as shown in FIG. 5. As best shown in FIGS. 5 and 7, the spiralbegins with the end marked 18A. The spiral is then rolled clockwisearound the end marked 18A until the outer small wire receiving opening18B overlaps the inner small wire receiving opening 18A and continuesaround until the outer large wire receiving opening 12B overlaps theinner large wire receiving opening 12A. As overlapped, the outer largewire strain relief slots 16B also overlap the large strain relief slots16A. When completely rolled, the terminal is a cylinder having an innerand outer wall of twice the thickness of the metal stamping and havingdiametrically opposed large and small wire receiving holes, 12 and 18,respectively, as best shown in FIG. 2. The terminal 10A thus includesfirst access means comprising inner and outer small wire openings 18Aand 18B, respectively and second access means comprising large wireinner and outer openings 12A and 12B, respectively. The blank 2 furtherincludes lower insulation displacement slots 24, and cap detention slots86A and 86B.

Referring now to FIGS. 8-11, the connector 10 includes a terminating cap50, which cooperates with terminal 10A and substantially closes the topend of connector 10. Cap 50 is molded from a dielectric material andincludes an outer wall 68 and an inner wall 66 interconnected by a topwall 58, the inner and outer walls 66,68 thereby defining an innerannular channel 62 therebetween. As shown in FIG. 11, cap 50 furthercomprises rotational lug 64 having surfaces 64A and 64B, detent latchmember 56 and small wire receiving channel 78. As shown in FIG. 8, thecap 50 includes hexagonal nut portion 60, continuity test hole 52 andwire entry hole 54. In typical configurations, the hexagonal nut portion60 rises so as to allow the terminal 10A to accommodate additionalsealant material, thereby improving the overall quality of theconnection. Wire entry hole 54 comprises large wire entry portion 54Aand small wire entry portion 54B, these portions being connected by afrusto-conical transition section defined by surface 76.

Referring now to FIG. 11, it is seen that inner circular wall 66 andouter circular wall 68 of cap 50 define inner channel 62, which is sodimensioned as to be slidably received over the top of terminal 10A:that is, the outer diameter of inner wall 66 is less than the innerdiameter of terminal 10A, while the inner diameter of outer wall 68 isgreater than the outer diameter of terminal 10A. When cap 50 is receivedover terminal 10A, wire receiving opening 54 in cap 50 is aligned withlarge wire receiving opening 12 and opposed small wire receiving opening18 in terminal 10A. Rotating cap 50 clockwise about a quarter turnaligns wire receiving hole 54 in cap 50 with the large wire receivingslot 14 and diametrically opposed small wire receiving slot 20. In fullyassembled form, the wire receiving openings 12 and 18 and the opening 54in cap 50 individually and together constitute connector body accessopenings.

Although the cap 50 and terminal 10A are rotatable with respect to oneanother, the angle through which the cap 50 may rotate is fixed, becauseas best shown in FIGS. 5 and 6, the terminal has rotational stops 32Aand 32B, and the cap in turn, as shown in FIG. 11, has a rotational stoplug 64, having surfaces 64A and 64B. When the cap 50 is received overterminal 10A such that the wire opening hole 54 in the cap 50 alignswith wire opening holes 12 and 18, surface 64B of lug 64 is againstsurface 32B of terminal 10A, and when the cap is rotated, the rotationis limited by surface 64A of lug 64 against surface 32A of terminal 10A.Thus, the angle of rotation is defined by the angle of surface 34 asdefined by surfaces 32A and 32B, less the included angle of lug 64, asdefined by surfaces 64A and 64B, and is the angle required to terminateeither the small wire or the large wire in the upper insulationdisplacement portion 8.

If a small wire is to be terminated, the small wire is placed in hole 54and extends through sections 54A, 54B and 54C, also passing throughlarge wire receiving opening 12, and then through small wire receivingopening 18 and into channel 78. When the cap is rotated relative to theterminal, the wire is carried in the channel, and the side wall ofchannel 78 forces the conductor into the small wire terminating slot 20,and the small wire makes electrical and mechanical contact with shearedsurfaces 21A and 21B at three points, because the width of at leastinner slot 20A is slightly smaller than the diameter of the small wireconductor. The small wire is also rotated into slot 14, and theinsulation of the small wire is gripped by slot 14, which acts as astrain relief. Conversely, when a large wire is placed in hole 54, thelarge wire passes through the large wire receiving opening 12 but thenis precluded from entering section 54B, and remains in section 54C,bearing against frusto-conical surface 76. When the cap is rotatedrelative to the terminal, the large wire is carried within hole 54 andthe large wire is forced into the large wire receiving slot 14 and thelarge wire makes electrical and mechanical contact with sheared surfaces15A and 15B at three points, because the width of at least inner slot14A is slightly smaller than the diameter of the large wire conductor.

According to preferred embodiments of the present invention, one or moreof the access openings 12, 18 and 54 are covered by a thin resilientfilm having a narrow slit or opening therein. As illustrated in FIG. 8A,for example, access opening 54 is covered by a thin resilient film 70having a narrow slit 71 therein. The wiper means according to suchembodiments preferably comprises thin polyurethane tape adhered to theterminal.

Another type of cap block for interconnecting a pair of wires isdisclosed in U.S. Pat. No. 5,006,077, which is incorporated herein byreference and with which the present invention may be used. A tubulardielectric housing has a center post therein defining an annular cavity.A stationary tubular terminal is affixed within the cavity adjacent thecenter post; a rotatable tubular terminal is disposed within the cavityconcentrically around the stationary terminal and in electricalengagement therewith at all times; and a lug-capped tubular actuator isalso mounted to the housing and is adapted to be rotated betweenactuated and unactuated positions to rotate the rotatable terminal. Apair of wire-receiving apertures extend through apertures through thehousing wall, through apertures of both terminals and the actuator, andat least into a center post aperture, all aligned in an unactuated statefor a wire end to be inserted thereinto. Preferably the terminal blockwould have a thin resilient slit film over the wire-receiving aperturesthrough the housing wall. Further, the probe opening through theactuator lug could be deepened to provide for sealant to move thereintoupon wire insertion. Upon rotation of the rotatable terminal by theactuator, slot walls of the terminal pierce the wire insulation andengage the wire's conductor. The stationary terminal includes a contactsection extending outwardly from the housing including insulationdisplacement slots for a wire to be inserted thereinto and terminated,for a multiconductor stub cable length to be secured to the enclosurecontaining a plurality of the terminal blocks, thus defining a cableharness. The two terminal members thus interconnect an appropriateconductor of the stub cable to a wire inserted into the terminal block.A second set of wire-receiving apertures can be utilized to receive asecond inserted wire end to be interconnected with the first and withthe stub cable connector.

Yet another type of terminal block is disclosed in U.S. patentapplication Ser. No. 07/708,405 filed May 31, 1991, which isincorporated herein by reference and which is assigned to the assigneehereof. Disclosed therein is a terminal block having a single-pieceterminal with connecting sections for two wires to be spliced, which areof the insulation piercing or displacement type which eliminates theneed for stripping the insulation from the signal wire conductors. Adielectric housing includes an integrally molded center post within atubular terminal-receiving housing section, both coextending from acommon base section and defining an annular cavity, the housing sectionproviding wire-receiving openings through side walls and into the cavityaligned with an aperture through the center post, enabling insertion ofwire ends during splicing. A barrel terminal and an associatedlug-capped tubular actuator is then assembled to the housing, with thebarrel terminal surrounding the center post within the cavity and havingapertured insulation displacement contact sections which are initiallyaligned with the wire-receiving openings of the housing and center post,and the actuator also having profiled apertures therethrough extendingpartially around the circumference and also aligned with thewire-receiving openings of the housing, center post and terminal. Thelug extends above the housing upon assembly to be accessible to toolingfor rotation thereof to rotate the actuator and the terminal. Again theprobe opening the actuator lug can be deep, and a film can cover thewire-receiving openings of the housing side wall. During splicing thewire ends of both wires are inserted into respective openings andthrough the apertured contact sections until stopped by abutment withcorresponding stop surfaces of the housing which then holds the wireends at two spaced locations, both outside and within the terminal wall;the actuator is then rotated thus rotating the terminal forcing the wireslot edges to pierce the wire insulation of both wires and electricallyconnect with the conductors therein.

B. Second Embodiment

While the first embodiment described above provides especially preferredreusable electrical connectors, it is contemplated that electricalconnectors according to other configurations are adaptable for use withthe present sealant compositions. For example, a second embodimentprovides a single use electrical connector, as illustrated in FIGS.12-14. Connectors of this type are also disclosed in U.S. Pat. No.3,410,950--Freudenberg, in U.S. Pat. No. 4,714,801--Koblitz et al., andin U.S. Pat. No. 5,004,869--Koblitz et al., each of which isincorporated herein by reference and assigned to the assignee of thepresent invention. These connectors are available from AMP Incorporatedunder the trade designation PICABOND®.

With particular reference now to FIGS. 12-14, a connector comprising aconnector 110 having transmission terminating means 116 is disclosed.The connector is comprised of an outer insulating film 114, an openU-type metal terminal 116 having a plurality of wire-receivingprojections 118 extending from inner surface 116A of terminal 116.Sealing material 112, and preferably the sealing composition of thepresent invention, is dispensed into the connector body 110 and in thisparticular embodiment it is deposited on the terminal 116, particularlyin the areas of projections 118. Connector 10 further has an innerinsulating film layer 120 therein which extends over the sealant 112 andprojections 118. Film layer 120 is sealed, preferably by means of heat,to the sides of the terminal 116 thus encasing the sealant material.

In using the connector 110, means for transmitting electrical current orsignals, such as wires 122, are inserted from opposite ends of theconnector 110 and disposed in the area of projections 118. As is shownin FIGS. 12 and 13, the wires 122 lie on top of the inner film layer120. FIG. 14 shows a cross-section of the crimped connector 110.Crimping of connector 110 generally requires exertion of force on theside walls 116B of the terminal 116 sufficient to deform the terminalinto a position similar to the one shown in FIG. 14, thereby forcing thewires 122 into receiving slots 124 of projections 118. Slots 124 arenarrower than the diameter of the conductors within wires 122 for sideedges of slots 124 to pierce the insulation surrounding the conductorsto establish electrical connections therewith. For the purpose ofconvenience, the force required to produce such a deformation isreferred to herein as the normal crimping force. As will be understoodby those skilled in the art, the magnitude of this force will varysomewhat depending upon several factors, including connector design andsize. During the crimping of the connector 110, wires 122 rupture thefilm layer as they are forced into receiving slots 124 of projection118. As a result of the pressure exerted by the normal crimping force,sealant 112 of the present invention is deformed as it is forced throughthe breach in the film layer 120 and surrounds the intersections of thewires and the projection, thereby sealing the immediate contact areasbetween the wires and the connector.

II. THE METHODS

It is contemplated that, in view of the information contained herein,compositions according to the present invention may be readily preparedusing known techniques. Nevertheless, it is preferred that the presentcompositions be prepared according to the methods described herein inorder to obtain compositions well adapted for use as sealants.

The methods of the present invention generally comprise the step ofproviding a solution, dispersion and/or emulsion of the elastomericthermoplastic polymer in the extender, and raising said solution,dispersion or emulsion to at least about the gelation initiationtemperature of the polymer/extender mixture, and even more preferably toat least about the fusion temperature of the polymer/extender mixture.As is well known to those skilled in the art, the application of heat topolymer/extender mixtures of the type disclosed herein generally causesphysical changes in the rheology of the mixture. Without intending to bebound by or limited to any particular theory, it is believed that uponthe application of heat to the solutions, dispersions or emulsions ofthe present invention, the extender portion thereof begins to becomesolvated in the polymer while fractions of the polymer dissolve in theextender. As additional heat is applied to the composition, continuedsolvation of the extender and the polymer results in a substantialincrease in viscosity and a corresponding loss of composition fluidity.This increase in viscosity and loss of fluidity is generally associatedwith the onset of the "gelation" of the composition. It will beappreciated by those skilled in the art that as the temperature israised from about room temperature to about the onset of gelation, thefluid polymer/extender compositions of the present invention may firstexhibit an initial decrease in viscosity, followed by the gradualincrease in viscosity described above. Upon application of further heatand a further increase in temperature, a peak in viscosity is reached,and thereafter the present compositions exhibit increasing fluency asthe gel becomes liquid-like. For the purposes of convenience, the term"gelation temperature range" is used herein to refer to the range oftemperature spanning from about the initial increase in compositionviscosity to about the end of the peak in viscosity. Techniques are wellknown and available to those skilled in the art for determining theonset of gelation of any particular polymer/extender composition. Forexample, the onset of gelation may be measured using a gelation platewhich is heated only at one end, thereby developing a temperaturegradient from one end of the plate to the other. When a polymercomposite/extender composition is cast onto the plate, the temperatureof the plate at the point the composition begins to lose its fluidity isreferred to herein as the composition's initial gelation temperature.The temperature at which the composition begins to regain fluidity isreferred to herein as the gelation end point. It will be appreciatedthat these terms are used for the purposes of convenience, but not byway of limitation.

The gelation temperature range of any particular composition is afunction of many variables, including the type and relative amounts ofextender and polymer material present. It is generally contemplated,however, that gelation of the present compositions will take place attemperatures of from about 125° C. to about 200° C. with sufficienttime. As additional heat is applied to the composition, incorporation ofthe extender into the polymer domains occurs and the composition becomesliquid-like. In particular, heating of the present compositions for atime sufficiently beyond the gelation end point causes the extendermolecules to become fully incorporated into the matrix of the polymermolecules, and the extender becomes substantially integrated into thepolymer network. In such a state, the composition is said to be a fusedliquid-like composition. According to certain embodiments, thecompletion of gelation is determined by monitoring the torque requiredby the mixer over time and noting the approximate peak torque thereofand its elapsed time.

Certain embodiments of the present methods preferably also comprise theimportant step of incorporating a crosslinkable polymer into thethermoplastic elastomer/extender mixture. It is especially preferredthat such an incorporating step comprise incorporating precursors forsaid crosslinkable polymer into a fluid composition comprising saidthermoplastic elastomer and then crosslinking said polymer precursors inthe presence of said thermoplastic elastomer. It is contemplated thatthe step of incorporating the crosslinked polymer precursors into thecomposition can occur, before, during and/or after the heating stepdescribed above. It is preferred, however, that the polymer precursorsbe added to the mixture after the initiation of gelation of the organicpolymer/extender mixture, more preferably after the gelation end pointis reached, and even more preferably after liquification of the organicpolymer/extender composition.

It is contemplated that the step of crosslinking the precursors in thepresence of the thermoplastic elastomer may utilize any one of severalwell-known techniques, and all such techniques are within the scope ofthe present invention. For embodiments in which the crosslinkablepolymer comprises crosslinkable silicon based polymer, it is preferredthat the polymer precursor comprise first and second functionalizedsilicon-based polymers wherein said first polymer is a hydrosiliconfunctionalized silicon-based polymer and said second polymer is a vinylfunctionalized silicon-based polymer. A suitable crosslinkablesilicon-based polymer is SYLGARD 527, obtainable from Dow CorningCorporation, Midland, Michigan. In such embodiments, the crosslinkingstep comprises introducing said first and second polymer precursors intothe thermoplastic elastomer/extender mixture during the heating thereof.It is also preferred that the crosslinking step comprise introducing acrosslinking catalyst, and preferably a platinum crosslinking catalyst,into the mixture before, during or after the introduction of saidpolymer precursors. It is believed that this chemical crosslinkingfurther enhances the thermal resistance of the sealant composition.

The examples which follow are illustrative but not limiting of thepresent invention.

III. EXAMPLES EXAMPLE 1

About 92 parts by weight (pbw) of an extender, about 1 pbw of a firstthermoplastic elastomeric polymer, about 4 pbw of a second thermoplasticelastomeric polymer, and about 5 pbw of fumed silica were introduced atroom temperature into a two liter heavy walled glass mixing beaker. Thebeaker was provided with a heating source and a three-bladed mixingpropeller. The extender was KAYDOL oil, sold by Witco, having akinematic viscosity of about 65-70 centistokes at 40° C., a specificgravity of about 0.87-0.89 at 25° C. and a pour point as measured byASTM D97 of about -18° C. The first thermoplastic elastomer was apoly(styrene-ethylene-butylene-styrene) triblock copolymer, availablefrom the Shell Development Corporation under the trademark KRATON G1651, having a styrene end block to ethylene and butylene center blockratio of about 33:67. As described in the Shell Company TechnicalBulletin SC1102-89, KRATON G 1651 has a melt viscosity of 42,700 whenpresent at a concentration of 5% in KAYDOL oil at 300° F. The secondthermoplastic elastomer was a low strength diblock copolymer,poly(styrene-ethylene-propylene), sold by Shell Development Corporationunder the trademark KRATON G 1701. As described in the Shell CompanyTechnical Bulletin SC1102-89, KRATON G 1701 has a melt viscosity of 209when present at a concentration of 5% in KAYDOL oil at 300° F. The fumedsilica was a fully hydrophobized 200 sq m/g amorphous silica sold underthe trademark AEROSIL R-974 by the Degussa Corporation.

With constant stirring by the three-bladed propeller at about 750 rpmthe temperature of the mixture was raised gradually from about roomtemperature to about 190° C. over a period of about 80 minutes toproduce a relatively homogenous, glutinous composition. Stirring wascontinued for about an additional 80 minutes as the temperature of themixture was lowered from about 190° C. to about 160° C. With the mixturetemperature at about 160° C., about 25 pbw of the SYLGARD 527 precursorsdescribed above was introduced gradually during a two minute period intothe glass mixing beaker. The mixture was maintained at about 160° C. andstirring was continued for about an additional 30 minutes.

After cooling 24 hours at room temperature the contents of the beakerwere observed to be a translucent homogenous, well dispersedthermoplastic gel sealant composition having a viscosity at 74° F. ofabout 266 units (0.1 mm) as measured by the ASTM D217 method for testingcone penetration of lubricating greases as described below.

ASTM D217 is a standard test procedure entitled "Standard Test Methodsfor Cone Penetration of Lubricating Grease," adopted by the AmericanSociety for Testing and Materials (ASTM) and used throughout thematerials industry to determine viscosities of lubricating greases. Thisprocedure was used to determine the cone penetration at 25° C. (77° F.)of a sample of the sealant that had received only minimum disturbance intransferring the sample to a grease worker cup or other suitablecontainer. The apparatus used was a penetrometer, which is designated tomeasure in tenths of a millimeter the depth to which a standard conepenetrates the sample. The penetrometer has an adjustable table toproperly position the cone on the surface of the sample prior toreleasing the cone. The standard cone used was made of magnesium with adetachable, hardened steel tip having a total weight of 102.5±0.1 g inaccordance with specifications of the test. A quantity of the sealantmaterial and the test sample container are brought to a temperature of25°±0.5° C. in a water or air bath. A sample of the material istransferred to the container and packed to eliminate air pockets. Thesample in the container is leveled and placed on the penetrometer table.The apparatus is adjusted so that the tip of the cone just touches thesurface of the sample. The cone shaft is then released and allowed todrop for 5.0±0.1 seconds. The amount of penetration is read from anindicator on the apparatus. In accordance with the procedure the valuesgiven are the average of three penetration tests per sample.

The physical properties of the sealant composition of this Example weremeasured and are reported in Table 1.

                  TABLE 1                                                         ______________________________________                                        Property Measured  Value                                                      ______________________________________                                        Appearance:        Translucent                                                Cone Penetration:  266                                                        (ASTM D217)                                                                   (units are 0.1 mm)                                                            Bleed 24 hrs. @ 80° C.                                                                    0                                                          (Fed Spec 321.1)                                                              Bleed 24 hrs. @ 100° C.                                                                   0                                                          (Fed Spec 321.1)                                                              Fineness of grind  8                                                          (ASTM D1210) (NS)                                                             Slump test                                                                     80° F., 24 hrs. (inch)                                                                   0.05                                                       100° F., 24 hrs. (inch)                                                                   0.3                                                        ______________________________________                                    

EXAMPLE 2

About 90 pbw of extender consisting of INDOPOL H-100 (polyisobutene) isintroduced at about room temperature into a mixing vessel provided witha heating source. INDOPOL H-100 is manufactured by Amoco and has akinematic viscosity of about 196-233 centistokes at 100° F., a specificgravity of about 0.88-0.90 at 60° F. and a pour point as measured byASTM D97 of about 20° F. The extender is heated to about 75° F. andmixed for about 15 minutes. About 0.75 pbw of KRATON G 1651 (S-EB-Striblock) and about 7.5 pbw of KRATON G 1701 (S-EP diblock) are thenadded to the mixing vessel and mixing was continued for about 15 minutesat a temperature of about 75° F. to produce a dispersion. About 0.5 pbwof antioxidant and thermal stabilizer,tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)] methane,sold by the Ciba-Geigy Corporation under the trademark IRGANOX 1010 isthen added to the mixture.

The mixture is maintained at about 375° F. and stirring is continued forabout an additional 120 minutes, at which point about 0.05 pbw ofcorrosion inhibitor, about 0.015 pbw of fungicide and about 0.05 pbw ofa surfactant are added to the mixing vessel. The corrosion inhibitor isbenzotriazole supplied under the trademark COBRATEC 99 by PMC,Incorporated, the fungicide is 2-(4-thiazdyl)benzimidazole suppliedunder the trademark METASOL™ TK-100 by Calgon Corporation and thesurfactant is a proprietary fluorinated esters non-ionic surfactantsupplied under the trademark FLUORAD FC430 by 3M Corporation. It isrequired to heat the mixture at temperature of about 420° F., withcontinual stirring for about an additional 120 minutes. The contents ofthe vessel are then cooled to about room temperature.

A clear, yellow gel sealant having the properties listed in Table 2below is produced.

                  TABLE 2                                                         ______________________________________                                        Property Measured  Value                                                      ______________________________________                                        Appearance:        Clear                                                      Cone Penetration:  300                                                        (ASTM D217)                                                                   (units are 0.1 mm)                                                            Softening Point: (°C.)                                                                     90                                                        Melt Flow: 3 sec., 0.8                                                        163° C. 30 psi (g/s)                                                   Pour point: (°C.)                                                                         200                                                        Slump test: 80° C.,                                                                       0.4                                                        24 hrs. (inches)                                                              Brookfield Viscosity:                                                                             35                                                        204° C. (poise)                                                        Oil retention:     100                                                        80° C. (percent)                                                       ______________________________________                                    

As can be seen from the results of this example, a sealant havingseveral desirable properties is produced. However, the viscosity andmelt flow characteristics are slightly below those desired for certainapplications.

EXAMPLE 3

Example 2 is repeated, except that the extender consists of 90 pbw ofKAYDOL (mineral oil), that is, the INDOPOL H-100 component of Example 2is replaced on a one-to-one basis by KAYDOL. KAYDOL oil is availablefrom the Sonneborn Company, a division of Witco Corp. and has akinematic viscosity of about 65-70 at 40° F., a specific gravity ofabout 0.87-0.89 at 25° C. and a pour point of about -18° F.

In addition, the final mixing step of this example only requires amixture temperature of about 375° as opposed to the additional mixing ata mixture temperature of about 420° F. required in Example 2.

A clear, water-white gel sealant having the properties listed in Table 3below is produced.

                  TABLE 3                                                         ______________________________________                                        Property Measured  Value                                                      ______________________________________                                        Appearance:        Clear                                                      Cone Penetration:  315                                                        (ASTM D217)                                                                   (units are 0.1 mm)                                                            Softening Point: (°C.)                                                                     95                                                        Melt Flow: 3 sec., 1.8                                                        163° C. 30 psi (g/s)                                                   Pour point: (°C.)                                                                         155                                                        Slump: 80° C.                                                                             0.8                                                        24 hrs. (inches)                                                              Brookfield Viscosity:                                                                             1                                                         204° C. (poise)                                                        Oil retention:     100                                                        80° C. (percent)                                                       ______________________________________                                    

As can be seen from the results of this example, a sealant which ishighly flowable, especially relative to the sealant of Example 2 isproduced. However, the sealant of this example exhibits an undesirablypoor slump resistance.

EXAMPLE 4

Example 3 is repeated, except that the extender consists of about 45 pbwof KAYDOL oil and about 45 pbw of INDOPOL.

A clear, nearly water-white, homogeneous high-temperature functional gelsealant according to the present invention having the properties listedin Table 4 below is produced.

                  TABLE 4                                                         ______________________________________                                        Property Measured  Value                                                      ______________________________________                                        Appearance:        Clear                                                      Cone Penetration:  315                                                        (units are 0.1 mm)                                                            Softening Point: (°C.)                                                                    105                                                        Melt Flow: 3 sec., 1.0                                                        163° C. 30 p.s.i. (g/s)                                                Pour point: (°C.)                                                                         200                                                        Slump: 80° C.,                                                                            0.2                                                        24 hrs. (inches)                                                              Brookfield Viscosity:                                                                             22                                                        204° C. (poise)                                                        Oil retention:     100                                                        80° C. (percent)                                                       ______________________________________                                    

As can be seen from the results of this example and a comparison toExamples 2 and 3, a sealant with unexpected and synergistic propertiesis produced. In particular, the sealant of this example not onlyexhibits slump resistance superior to the sealants of either of theprevious examples, it even more surprisingly has melt flow and softeningpoint characteristics which are also superior to the sealants of theprior examples.

The sealant of this example is tested for operability in a connector ofthe type described in the first connector embodiment hereof and sold byAMP Incorporated under the trade name, "Quiet Front". Theelectrical/thermal/environmental insulating capacity of the sealant ofthis example is tested by injecting the sealant into 30 samples of theconnector. Ten samples each of the sealed connectors are testedaccording to the Bellcore Technical Reference TR-NWT-00975 (hereinaftertermed "the Bellcore Reference") pursuant to sections 3.41, 3.42 and3.43. All samples satisfy the requirements of the specified testconditions.

The sealant of this example also satisfies the insulation resistancerequirements specified in sections 3.1 of the Bellcore Reference. Tenconnectors sealed by the sealant of this example were also subject tothe test procedures specified in section 3.4.4 of the Bellcore Referencedirected to measurement of stress relaxation and strain release. All ofthe samples met the requirements of this section. The connectors alsopassed the vibration, flex and compatibility standards set forth in theBellcore Reference.

EXAMPLE 5

Example 4 is repeated except that about 3.0 pbw of a temperaturestabilizing agent based on fully hydrophobized surface treated amorphoussilica available from Degussa Corporation under the designation "AEROSILR-974" is added to the mixture at the additional 120 minute point.

A clear, homogenous, high-temperature functional gel sealant having theproperties listed in Table 5 below is produced.

                  TABLE 5                                                         ______________________________________                                        Property Measured  Value                                                      ______________________________________                                        Appearance:        Clear                                                      Cone Penetration:  292                                                        (ASTM D217)                                                                   (units are 0.1 mm)                                                            Softening Point: (°C.)                                                                     95                                                        Melt Flow: 3 sec., 0.7                                                        163° C. 30 p.s.i. (grams)                                              Pour point: (°C.)                                                                         185                                                        Slump: 80° C.,                                                                            0.05                                                       24 hrs. (inches)                                                              Brookfield viscosity:                                                                             42                                                        204° C. (poise)                                                        Oil retention:     100                                                        80° C. (percent)                                                       ______________________________________                                    

EXAMPLE 6

The composition of Example 4 was tested for its ability to protect avariety of different electrical connectors from water intrusion. Thetest protocol was based on the water immersion test specified in theBellcore Reference which is incorporated herein by reference.

A first connector of the type described hereinabove and sold by AMPIncorporated under the trade name, Quiet Front was tested. A secondconnector of the type described hereinabove and sold by AMP Incorporatedunder the trade name, PICABOND® was also tested. A third connector soldby AMP Incorporated under the trade name, Tel-Splice, and described inAMP Instruction Sheet IS6502 was also tested. A fourth connectoravailable under the trade designation, Automotive Diagnostic Connector,AMP Incorporated Part Number 776002 was also tested.

To perform the test an electrical connector containing the sealantcomposition of Example 4 was prepared. The connectors containing thesealant composition were immersed to a depth of 6 inches in a aqueous 5%NaCl salt solution. The connectors were then energized with a 48 volt dcpotential applied between common sample leads and a copper electrodeimmersed in the basin. To confine the short circuit current toapproximately 20 milliamperes, limiting resistors were placed in serieswith each sample. The insulation resistance between individualconnectors and the water were measured at 1 hour, at 7 days and finallyat 14 days using a 250 volt DC potential. A minimum insulationresistance (IR) criterion of 1×10⁸ ohms was used as a fail point for allconductors. All test procedures were performed at ambient laboratoryconditions. The immersion test results for each of the different typesof connectors is presented below.

                                      TABLE 6                                     __________________________________________________________________________    INSULATION RESISTANCE RESULTS FOR QUIET FRONT                                 CONNECTORS                                                                    CONTAINING THE SEALANT COMPOSITIONS OF EXAMPLE 4                              Condition                                                                              Initial Aft. 1 Hr.                                                                           Aft. 7 days                                                                           Aft. 14 days                                  __________________________________________________________________________    # Samples                                                                              12      12     12      12                                            Min. IR Ω                                                                        2 × 10.sup.10                                                                   2 × 10.sup.10                                                                  4 × 10.sup.10                                                                   4 × 10.sup.10                           Max. IR Ω                                                                        3 × 10.sup.10                                                                   2 × 10.sup.10                                                                  4 × 10.sup.10                                                                   2 × 10.sup.11                           Mean IR Ω                                                                        2.2 × 10.sup.10                                                                 2.0 × 10.sup.10                                                                2.0 × 10.sup.10                                                                 2.2 × 10.sup.10                         # < 1 × 10.sup.8 Ω                                                         0       0      0       0                                             __________________________________________________________________________

Results show that no leakage occurred on any silo during the two weeksof immersion testing. All samples maintained an insulation resistance ofgreater than 1×10⁸ ohms.

                                      TABLE 7                                     __________________________________________________________________________    INSULATION RESISTANCE RESULTS FOR TEL-SPLICE                                  CONNECTORS                                                                    CONTAINING THE SEALANT COMPOSITION OF EXAMPLE 4                               Condition                                                                              Initial Aft. 1 Hr.                                                                           Aft. 7 days                                                                           Aft. 14 days                                  __________________________________________________________________________    # Samples                                                                              10      10     10      10                                            Min. IR Ω                                                                        1 × 10.sup.10                                                                   2 × 10.sup.10                                                                  1 × 10.sup.10                                                                   3 × 10.sup.10                           Max. IR Ω                                                                        2 × 10.sup.10                                                                   3 × 10.sup.10                                                                  2 × 10.sup.10                                                                   1 × 10.sup.11                           Mean IR Ω                                                                        1.8 × 10.sup.10                                                                 2.3 × 10.sup.10                                                                1.9 × 10.sup.10                                                                 6.0 × 10.sup.10                         # < 1 × 10.sup.8 Ω                                                         Ω Ω                                                                              Ω Ω                                       __________________________________________________________________________

The Tel-Splice samples also maintained an IR of greater than 1×10⁸ ohmsthroughout the immersion test.

                                      TABLE 8                                     __________________________________________________________________________    INSULATION RESISTANCE RESULTS FOR DIAGNOSTIC CONNECTORS                       CONTAINING THE SEALANT COMPOSITION OF EXAMPLE 4                               Condition                                                                              Initial Aft. 1 Hr.                                                                           Aft. 7 days                                                                           Aft. 14 days                                  __________________________________________________________________________    # Samples                                                                              10      10     9       8                                             Min. IR Ω                                                                        1 × 10.sup.9                                                                    4 × 10.sup.9                                                                   4 × 10.sup.10                                                                   1 × 10.sup.10                           Max. IR Ω                                                                        6 × 10.sup.9                                                                    4 × 10.sup.10                                                                  1 × 10.sup.11                                                                   2 × 10.sup.11                           Mean IR Ω                                                                        3.1 × 10.sup.9                                                                  7.9 × 10.sup.9                                                                 8.8 × 10.sup.10                                                                 1.6 × 10.sup.11                         # < 1 × 10.sup.8 Ω                                                         0       0      1       2                                             __________________________________________________________________________

All PICABOND connectors failed the immersion test initially. It isexpected that this result occurred because of the particular elastomericproperties of the sealant of Example 4. Nevertheless, it is contemplatedthat appropriate modification of the Example 4 sealant within the scopeof the present invention is capable of producing satisfactory immersiontest results.

EXAMPLE 7

The composition of Example 4 is tested for its ability to reliablyprotect Quiet Front type connectors of the type described in the firstembodiment hereof and sold by AMP Incorporated under the trade name,Quiet Front, from water intrusion. The test protocol is based on thewater immersion test described in Example 6.

Three hundred Quiet Front connectors containing the sealant compositionof Example 4 were prepared. The connectors containing the sealantcomposition were immersed to a depth of 6 inches in an aqueous 5% NaClsalt solution and tested as in Example 4. An unusually large number ofcircuits passed the test even after 14 days of immersion, as reported inTable 9 below.

                  TABLE 9                                                         ______________________________________                                        PERCENTAGE OF CIRCUITS PASSING                                                THE IMMERSION TEST                                                            Time      Initial    Aft. 7 Days                                                                             Aft. 14 days                                   ______________________________________                                        # samples 293        280       259                                            passing                                                                       % samples 97.6       93.3      86.3                                           passing                                                                       ______________________________________                                    

EXAMPLE 8

The composition of Example 4 is tested according to ASTM D4048 topredict its ability to protect electrical connections from environmentalcorrosion. ASTM D4048 measures the amount of copper strip corrosionresulting from exposure to a sealant. Utilizing the classificationparameters described in ASTM D4048, the composition of Example 4 isclassified as 1B. This classification indicates that the composition ofExample 4 does not result in corrosion and causes only slight tarnishingof a copper strip and is therefore very well suited for electricalconnection applications.

EXAMPLE 9

About 90 pbw of extender consisting of about 45 pbw of a KAYDOL oil andabout 45 pbw of INDOPOL is introduced at about room temperature into amixing vessel provided with a heating source. The extender is heated toabout 75° F. and mixed for about 15 minutes. About 7.5 pbw of KRATON G1701 (S-EP diblock) is then added to the mixing vessel and mixing iscontinued for about 15 minutes at a temperature of about 75° F. toproduce a dispersion. About 0.5 pbw of antioxidant/thermal stabilizersold by the Ciba-Geigy Corporation under the trademark IRGANOX 1010 isthen added to the mixture.

The mixture is maintained at about 375° F. and stirring is continued forabout an additional 120 minutes, at which point about 0.05 pbw ofcorrosion inhibitor, about 0.015 pbw of fungicide and about 0.05 pbw ofa surfactant are added to the mixing vessel. The corrosion inhibitor isbenzotriazole supplied under the trademark COBRATEC 99 by PMC,Incorporated, the fungicide is 2-(4-thiazdyl)benzimidazole suppliedunder the trademark METASOL TK-100 by Calgon Corporation and thesurfactant is a proprietary fluorinated esters non-ionic surfactantsupplied under the trademark FLUORAD FC430 by 3M Corporation. It isrequired to maintain the mixture at temperature of about 375° F., withcontinual stirring for about an additional 120 minutes. The contents ofthe vessel are then cooled to about room temperature.

A clear, yellow gel sealant having the properties listed in Table 10below is produced.

                  TABLE 10                                                        ______________________________________                                        Property Measured  Value                                                      ______________________________________                                        Appearance:        Clear                                                      Cone Penetration:  365                                                        (ASTM D217)                                                                   (units are 0.1 mm)                                                            Softening Point: (°C.)                                                                    pourable at RT                                             Melt Flow:         >3.3                                                       163° C. 30 psi (g/s)                                                   Slump: 80° C.,                                                                            >4.5                                                       24 hrs. (inches)                                                              Oil retention:     100                                                        80° C. (percent)                                                       ______________________________________                                    

As can be seen from the results of this example, a generallyunacceptable sealant composition is produced when only a primary polymer(S-EP diblock) is present in the composition. In particular, the slumpresistance, melt flow and softening point characteristics indicate thatsuch a sealant will not remain in the connector and/or will notadequately seal electrical connections under the preferred operatingtemperature range.

EXAMPLE 10

Example 9 is repeated, except that the primary polymer consisted of 7.5pbw of KRATON G 1701 and (S-EP diblock) and about 0.75 pbw of KRATON G1652 (S-EB-S triblock).

A clear, yellow gel sealant having the properties listed in Table 11below is produced.

                  TABLE 11                                                        ______________________________________                                        Property Measured  Value                                                      ______________________________________                                        Appearance:        Clear                                                      Cone Penetration:  354                                                        (ASTM D217)                                                                   (units are 0.1 mm)                                                            Softening Point: (°C.)                                                                    pourable at RT                                             Melt Flow:         >3.3                                                       163° C., 30 psi (g/s)                                                  Slump: 80° C.,                                                                            >4.5                                                       24 hrs. (inches)                                                              Oil retention:      0                                                         80° C. (percent)                                                       ______________________________________                                    

As can be seen from the results of this example, a generallyunacceptable sealant composition is produced even when a primary polymercontaining-both diblock and triblock copolymer components is present inthe composition. In particular, the slump resistance, spew resistance,melt flow and softening point characteristics indicate that such asealant will not remain in the connector and/or will not adequately sealelectrical connections under the preferred temperature range indicatedabove.

EXAMPLE 11

Example 9 is repeated, except that in addition to the primary polymer(S-EP diblock), about 0.75 pbw of the secondary polymer KRATON G 1651(S-EB-S triblock) is added to the composition.

A clear gel sealant having the properties listed in Table 12 below isproduced.

                  TABLE 12                                                        ______________________________________                                        Property Measured  Value                                                      ______________________________________                                        Appearance:        Clear                                                      Cone Penetration:  305                                                        (ASTM D217)                                                                   (units are 0.1 mm)                                                            Softening Point: (°C.)                                                                    108                                                        Melt Flow:         1.1                                                        163° C., 30 psi (g/s)                                                  Slump: 80° C.,                                                                            0.10                                                       24 hrs. (inches)                                                              Oil retention:     100                                                        80° C. (percent)                                                       ______________________________________                                    

As can be seen from the results of this example and a comparison toExamples 9 and 10, a sealant with unexpected and dramatically improvedproperties is produced. In particular, the sealant of this exampleexhibits a slump resistance which is about 150 times superior to eitherof the previous examples. Furthermore, the melt flow characteristics areabout 3 times superior to the sealants of the prior examples.

EXAMPLE 12

The composition of Example 4 is used in a method of manufacturing sealedelectrical connectors of the type sold by AMP Incorporated under thetrade names, Tel-Splice and Quiet Front. These connectors havepreviously been sold containing grease-type sealants or not containingsealants.

The Quiet Front terminal blocks containing six silos per block arefilled and sealed by intermittent "shots" of the composition of Example4. The filling apparates is the PAM-Model 500-E hot melt extrusion gunwith AMP nozzle hereinbefore described. The gun was loaded with about 50g. of sealant composition.

Each silo is filled by triggering bursts of sealant for about one-fourthto one-half second until the sealant extrudes from the lug to siloflanges using an air pressure of 30 psig. at 325° F. The lug is in theclosed (terminated) position while filling. The filling port is the testprobe port with the silos vertical and the test probe port openingupward. The lower and upper wire entry ports are closed by rubber pads.The terminal block is allowed to cool to room temperature overnight, andthe gain in weight of the blocks is measured. About 1.4 g of sealant persilo is found. This agrees reasonably with the predetermined 1.4 cc.volume of the silos.

The insulation resistance test described in Example 6 is performed onthe filled blocks with no leakage occurring on any silo on initialtesting.

The same apparatus and filling conditions are used in filling 10Tel-Splice connectors. The top members of the housings are removed whilethe bottom members are filled by short bursts until the back sides ofthe termination members are covered. The top members are then replaced,expressing forward the sealant composition to slackly fill the case.Filling is completed by injecting through a wire entry hole until thecase is filled visually bubble-free.

The splices are weighed to find the average weight gain of sealantcomposition per splice. This is found to be about 0.12 g per splice,which agrees reasonably with the predetermined 0.12 cc. volume of thesplice.

The insulation resistance test of Example 6 is performed on the filledsplices with no leakage occurring on any splice on initial testing.

We claim:
 1. A moisture and temperature resistant electrical connectorfor sealingly connecting transmission means comprising:(a) a connectorbody comprising a substantially closed container having access means forallowing entry of said transmission means into said connector body and aterminal means for accepting and electrically connecting with saidtransmission means; and (b) a sealant composition substantially fillingsaid container and disposed along or adjacent to said terminal means,said sealant composition comprising an elastomeric thermoplastic polymercomposite and an extender for said polymer composite, said extendercomprising a major proportion by weight of said composition and saidpolymer composite comprising a minor proportion by weight of saidcomposition, wherein said polymer composite includes a mixture of(i) atriblock copolymer and (ii) a diblock copolymer, the weight ratio ofsaid triblock copolymer to said diblock copolymer being in the range ofabout 1:20 to about 1:5; and wherein said extender includes(i) a primaryextender for said polymer, said primary extender being selected from thegroup consisting essentially of C₁ -C₄ polyolefins and (ii) a secondaryextender for said polymer, said secondary extender being selected fromthe group consisting essentially of mineral oil the weight ratio of saidprimary extender to said secondary extender being in the range of about50:50.
 2. The connector of claim 1 in which the weight ratio of saidextender to said polymer is in the range of about 9.5:0.5 to about85:15.
 3. The connector of claim 2 wherein said weight ratio of saidextender to said polymer is about 93:7 to about 8:2.
 4. The connector ofclaim 1 wherein said weight ratio of said triblock copolymer to saiddiblock copolymer is in the range of about 1:20 to about 1:10.
 5. Theconnector of claim 1 wherein said diblock copolymer comprises a block ofnon-elastomeric polymer connected to a block of elastomeric polymer,said non-elastomeric polymer block being selected from the groupconsisting of poly(alkenyl arenes), polyurethanes and combinations ofthese, and said elastomeric polymer block being selected from the groupconsisting of non-aromatic polyolefins, polyesters, polyethers andcombinations of these.
 6. The connector of claim 5 wherein saidnon-elastomeric polymer block comprises a poly(alkenyl arene) and saidelastomeric polymer block comprises a non-aromatic polyolefin.
 7. Theconnector of claim 6 wherein said non-elastomeric polymer blockcomprises polystyrene and said elastomeric polymer block comprises aC1-C6 non-aromatic polyolefin.
 8. The connector of claim 7 wherein saidnon-elastomeric polymer block comprises polystyrene and said elastomericpolymer block comprises poly(ethylene-propylene).
 9. The connector ofclaim 1 wherein said triblock copolymer comprises a block ofnon-elastomeric polymer connected to a block of elastomeric polymer,said block of elastomeric polymer being connected to another block ofnon-elastomeric polymer, said non-elastomeric polymer block beingselected from the group consisting of poly(alkenyl arenes),polyurethanes and combinations of these, and said elastomeric polymerblock being selected from the group consisting of non-aromaticpolyolefins, polyesters, polyethers and combinations of these.
 10. Theconnector of claim 9 wherein said non-elastomeric block comprises apoly(alkenyl arene) and said elastomeric block comprises a non-aromaticpolyolefin.
 11. The connector of claim 10 wherein said non-elastomericblock comprises polystyrene and said elastomeric block comprises a C₁-C₆ non-aromatic polyolefin.
 12. The connector of claim 11 wherein saidelastomeric polymer block comprises poly(ethylene-butylene).
 13. Theconnector of claim 1 wherein said weight ratio of said primary extenderto said secondary extender is in the range of about 40:60 to about60:40.
 14. The connector of claim 1 wherein said primary extendercomprises a C₄ polyolefin.
 15. The connector of claim 14 wherein saidprimary extender is selected from the group consisting of polybutene,polybutadiene and polyisobutene.
 16. The connector of claim 1 whereinsaid mineral oil compresses white oil.
 17. The connector of claim 1wherein said composition further comprises fumed silica.
 18. Theconnector of claim 17 wherein said composition further comprises lessthan about 8 percent by weight of fumed silica.
 19. The connector ofclaim 18 wherein said composition comprises from about 0.1 to about 6.0percent by weight of fumed silica.
 20. The connector of claim 19 whereinsaid fumed silica is selected from the group consisting of hydrophobicsurface treated amorphous silica, hydrophilic amorphous silica andmixtures of these.
 21. The connector of claim 1 wherein said compositionfurther comprises a crosslinked polymer.
 22. The connector of claim 21wherein said crosslinked polymer comprises an inorganic crosslinkedpolymer.
 23. The connector of claim 22 wherein said inorganiccrosslinked polymer comprises a crosslinked silicon-based polymer. 24.The connector of claim 23 wherein said crosslinked silicon-based polymeris selected from the group consisting of polysilanes, polysiloxanes,polysilalkylenes, and polysilarylenes.
 25. The connector of claim 24wherein said crosslinked silicon-based polymer comprises a polysiloxane.26. The connector of claim 21 wherein said inorganic crosslinked polymercomprises less than about 35 percent by weight of said composition. 27.The connector of claim 26 wherein said inorganic crosslinked polymercomprises less than about 25 percent by weight of said composition. 28.The connector of claim 21 wherein said organic elastomeric thermoplasticpolymer and said inorganic crosslinked polymer together comprise lessthan about 20 percent by weight of the composition.
 29. The connector ofclaim 28 wherein said organic elastomeric thermoplastic polymer and saidinorganic crosslinked polymer together comprise less than about 15percent by weight of the composition.
 30. The connector of claim 1wherein said composition comprises:about 45 parts by weight of mineraloil, about 45 parts by weight of polyisobutene, about 0.75 part byweight of poly(styrene-ethylene-butylene-styrene) triblock copolymer,about 7.5 parts by weight of poly(styrene-ethylene-propylene) diblockcopolymer, about 0.5 part by weight of antioxidant/thermal stabilizer,about 0.05 part by weight of corrosion inhibitor, about 0.015 part byweight of fungicide, and about 0.05 part by weight of surfactant. 31.The connector of claim 1 wherein said triblock copolymer consistsessentially of poly(alkenyl arene) non-elastomeric polymer blockmaterial and non-aromatic polyolefin elastomeric polymer block material,andsaid diblock copolymer consists essentially of poly(alkenyl arene)non-elastomeric polymer block and non-aromatic polyolefin elastomericpolymer block material.
 32. The connector of claim 31 wherein saidnon-elastomeric polymer block material of said triblock copolymerconsists essentially of polystyrene,said elastomeric block material ofsaid triblock copolymer consists essentially of C₁ -C₆ non-aromaticpolyolefin, said non-elastomeric polymer block material of said diblockcopolymer consists essentially of polystyrene, said elastomeric blockmaterial of said diblock copolymer consists essentially of C₁ -C₆non-aromatic polyolefin, said primary extender consists essentially of aC₄ polyolefin, and said secondary extender consists essentially of amineral oil.
 33. The connector of claim 32 wherein said elastomericblock material of said triblock copolymer consists essentially ofpoly(ethylene-butylene),said elastomeric block material of said diblockcopolymer consists essentially of poly(ethylene-propylene), and saidprimary extender consists essentially of a polyisobutene oil.
 34. Theconnector of claim 31 wherein said weight ratio of said triblockcopolymer to said diblock copolymer is about 1:10.
 35. A method ofmanufacturing a moisture and temperature resistant electrical connectorfor sealingly connecting transmission means comprising:(a) a connectorbody comprising a substantially closed container having access means forallowing entry of said transmission means into said connector body and aterminal means for accepting and electrically connecting with saidtransmission means; and (b) a sealant composition substantially fillingsaid container and disposed along or adjacent to said terminal means,said sealant composition comprising an elastomeric thermoplastic polymercomposite and an extender for said polymer composite, said extendercomprising a major proportion by weight of said composition and saidpolymer composite comprising a minor proportion by weight of saidcomposition, wherein said polymer composite includes a mixture of(i) atriblock copolymer and (ii) a diblock copolymer, the weight ratio ofsaid triblock copolymer to said diblock copolymer being in the range ofabout 1:20 to about 1:5; and wherein said extender includes (i) aprimary extender for said polymers, said primary extender selected fromthe group consisting of C₁ -C₄ polyolefins and (ii) a secondary extenderfor said polymer, said secondary extender being selected from the groupconsisting essentially of mineral oil, the weight ratio of said primaryextender to said secondary extender being in the range of about 50:50.36. The method of claim 35 in which the weight ratio of said extender tosaid polymer is in the range of about 9.5:0.5 to about 85:15.
 37. Themethod of claim 36 wherein said weight ratio said extender to saidpolymer is about 93:7 to about 8:2.
 38. The method of claim 25 whereinsaid weight ratio of said triblock copolymer to said diblock copolymeris in the range of about 1:20 to about 1:10.
 39. The method of claim 35wherein said weight ratio of said primary extender to said secondaryextender is in the range of about 40:60 to about 60:40.
 40. The methodof claim 35 wherein said triblock copolymer comprises poly(alkenylarene) non-elastic polymer block material and non-aromatic polyolefinelastomeric polymer block material, and said diblock copolymer consistsessentially of polymer(alkenyl arene) non-elastic polymer block materialand non-aromatic polyolefin elastomeric polymer block material.
 41. Themethod of claim 40 wherein said elastomeric polymer block material ofsaid triblock copolymer consists essentially of poly(ethylene-butylene),said elastomeric polymer block material of said diblock copolymerconsists essentially of poly(ethylene-propylene) and said primaryextender consists essentially of polyisobutene oil.
 42. The method ofclaim 41 wherein said weight ratio of said triblock copolymer to saiddiblock copolymer is about 1:10.
 43. The method of claim 2 wherein saidmineral oil comprises white oil.